7/30/2019 Tender Doc NALCO Agon Tipper Part II http://slidepdf.com/reader/full/tender-doc-nalco-agon-tipper-part-ii 1/298 NATIONAL ALUM INIUM COM PANY LIMITED BID DOCUM ENT No . : WT/01/2011/RITES/NALCO-ANGUL PACKAGE - I TENDER DOCUM ENT FOR DESIGN, M ANUFACTURE, SUPPLY, ERECTION, TESTING AND COM M ISSIONING OF WAGON TIPPLER AND CONVEYOR SYSTEM FOR M /S. NALCO AT ANGUL. PART – II CONTENTS 1. GENERAL 2. INTENT OF SPECIFICATIONS 3. INSTRUCTION TO BIDDERS 4. SYSTEM PARAM ETERS, OPERATION AND CONTROL PHILOSOPHY 5. GENERAL TECHNICAL REQUIREM ENTS 6. ELECTRICAL 7. CONDITION OF CONTRACT FOR FIELD SERVICES 8. ANNEXURES (A GOVERNM ENT OF INDIA ENTERPRISE) PROJECT OFFICE BHAGWAN TOWER, 1 ST FLOOR CUTTACK ROAD, BHUBANESW AR – 751006
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3 .5 There are two (2) underground conveyors a t bo t tom o f each t rack hopper . Both
conveyors are running paral le l at the bottom of the track hopper–1. The paral le l
conveyor ins ta lled a t the bo t tom o f t rack hopper–2 run in opp osite d i rect ion .
3 .6 There are two (2) Bunker Bays. The old Bunker Bay meets the crushed coal
requ i rement fo r Un i t 1 – 6 whereas the new Bunker Bay meets the crushed coa l
requ i rement fo r un i t 7 to 10 . Thus, there are t w o separa te conveyor pa ths. Each path
has tw o conveyor stream s runn ing in paralle l .
3 .7 Rated & designed capaci ty of each conveyo r stream is 800 TPH & 960 TPH respectively.
3 .8 Two paral le l conveyors wi th moving tr ipper are instal led on the top of each Bunker
Bay. One moving tr ipper is provided on each conveyor instal led on the top of Bunker
Bay. M oving tr ipp ers feed th e crushed coal in desired bun kers as per requ irement .
3 .9 The CHP has two (2) Crusher Houses. The old crusher hou se is provided on conveyor
path that is feeding crushed coal to Un i ts 1- 6. The new crusher house is prov ided on
conveyor pa th t ha t is convey ing crushed coa l to Un i t 7 t o 10 .
3.10 Each crusher h ouse has two (2) crushers & associated equipm ent instal led on paral lel
conveyor ser ies. Thus, each crusher ser ies has been p rovided w ith dedicated crusher
and associated equipm ent.
3.11 There are three uncrushed coal storage yards with stacker cum recla imer machine(SCR) in p resent CHP. One SCR machin e is prov ided on each sto rage yard.
conveyor BC-116 wi l l be conveyed to the new crusher house through exist ing bel t
conveyor system for supplying the crushed coal to b unkers of uni t 7 -10.
4 .6 Extension of ta i l end of exist ing conveyor BC - 104 f rom exist ing Junct ion Hou se JH-2 to
new Junction House JH-13 to receive recla imed uncrushed coal from the Addit ional
Coal Storage Yard through a new conveyor BC-120 and BC-121.Uncrushed coal
received on th e extended con veyor BC-104 shal l be Conveyed t o t he old crusher hou se
th rou gh the exist in g bel t conveyor system for supplying crushed coal to the bun kers of
un i t # 1 -6 .
4 .7 For Receipt of un crushed coal fo r t he pro posed Addit ional Coal Stor age and Hand l ing
System, uncrushed coal conveyed to JH-7 by existing conveyor BC-115 from Track
Hopper N o.2 can be d iverted e i ther to ex ist ing conveyor BC-116 o r t o n ew conveyorBC-118A at Junction House JH-7. The new conveyor BC-118A wi l l convey mater ia l to
the proposed Addit ional Coal Storage Yard through a new conveyor system under
development. For th is, the exist ing Junction House JH-7, shal l be modif ied to
accommodate the ta i l end of new conveyor BC-118A. The discharge chute of the
exist ing conveyor BC-115 shal l be replaced with new chute arrangement having a two
way chute wi th a f lap gate . Two-way chute wi th f lap gate wi l l d iver t the mater ia l
d ischarged from conveyor BC - 115 ei ther to exist ing conveyor BC-116 or to the new
conveyor BC-118A depend ing on posi t ion of t he gate.
The discharge pul ley of exist ing conveyor BC-115 wi l l be re located sui tably to ensureth e f low of uncru shed coal , e i ther t o conveyor BC-116 or to th e new conveyor BC-118A
is smooth th rough the new f lap gate and chute ar rangement . The ra ted capaci ty o f
convey ing system is 800 t /h r .
4 .8 For sto rage of un crushed coal in th e Addit ional Coal Sto rage Yard und er developm ent,
the coal received through conveyor BC-118A wi l l be conveyed to the Yard through
con veyor s BC-119 & BC-120 and n ew Jun ction Hou ses JH-10 & JH-11. The conveyo r BC-
120 wi l l be equipped with a Slew Stacker Machine. The Slew Stacker Machine wi l l be
capable of forming two identical stock pi les of uncrushed coal on ei ther side of i ts
tr ack. The length o f each stock pi le w i l l be 275 m . The storage capaci ty o f each StockPile wi l l be 45,000 t of u ncrushed coal . The rated capacity o f stacking system is 800 t / hr
4 .9 For Reclaim ing th e uncru shed coal fr om Addit ion al Coal Storage Yard, a Bucket W heel
Reclaim er w i l l be p rovided. The Bucket W heel Reclaimer w i l l be instal led on con veyor
BC -120 such that i ts d ischarge is col lected on the yard conveyo r BC-120. The BW R wi l l
be op erat ing on th e sam e track as that o f th e Slew Stacker M achine. Simu ltaneou s
operat ion of stacking and recla iming is a lso proposed on the yard conveyor BC-120.
Uncrushed coal recla imed o n conveyor BC-120 wi l l be conveyed t o new Junct ion Hou se
JH-12. The rat ed capaci ty of t he recla iming system shal l be 800 t/ hr .
4.10 Conveyor BC-120 w i l l convey r eclaim ed m ater ia l to new Junct ion Hou se JH-12. Head/
d ischarge end o f conveyor BC-120 w i ll be prov ided w i th tw o w ay chute w i th f lap gate
arrangement. Depending on posi t ion of f lap gate in the discharge chute, uncrushed
coal recla imed from the Addit ional Coal Storage Yard wi l l be diverted ei ther to
conveyor BC-121 or to conveyor BC-122 at new Junction House JH-12. Conveyor BC-
121 wi l l t ranspor t the mater ia l to new JH-13 and t ransfer mater ia l to the ta i l end o f
exist ing and extend ed conveyor BC-104, Conveyor BC-122 w i l l con vey th e m ater ia l to
new Junction House JH-7A and transfer the mater ia l to ta i l end of exist ing and
extend ed conveyor BC-116. The rated capaci ty of con veying system is 800 t/ hr .
4.11 Conveying of uncrushed coal to new crusher house. Uncrushed coal received on
conveyor BC-122 wi l l be conveyed to new Junction House JH-7A, located adjacent toexisting JH-7. At Jun ctio n Hou se JH-7A, conveyo r BC-122 shall dischar ge th e uncru shed
coal at th e extended ta i l end o f exist ing conveyor BC-116. Uncrushed coal received o n
conveyor BC-116 wi l l be conveyed to the new crusher house through the exist ing coal
f low path . The rated capaci ty of conveying system is 800 t/ hr .
4.12 For Conveying the uncrushed coal to the old crusher house, uncrushed coal received
on conveyor BC-121 shal l be conveyed to new Junction House JH-13. At th is new
Junct ion Hou se JH-13, conveyor BC-121 w i ll d ischarge the m ater ia l to the extended ta i l
end of the exist ing conveyor BC-104. Coal received on conveyor BC-104 wi l l be
conveyed t o t he o ld crusher house th rough ex ist ing coa l f low path .
The ta i l end of exist ing conveyor BC-104 at JH-2 wi l l be extended up to the new
Junct ion Ho use JH-13 and a n ew conveyor gal lery b etw een exist ing Junction House JH-
2 and the new Junction House JH-13 wi l l be provided to house the extended length of
exist ing conveyo r BC-104. The system rated capaci ty is 800 t / hr .
4.13 Dust Suppression System wi l l be provided at a l l t ransfer points at var ious Junction
Houses and u ncrushed coal storage yard.
4.14 Suitable venti lat ion and air condi t ioning faci l i t ies wi l l be provided in Switch gear cumM CC room , Bat te ry room , Transformer ro om s.
4.15 PLC based op erat ion & cont rol system is being provided for add i t ional coal stor age &
handl ing system . Cont rols are being sui tably in ter faced w ith exist ing conveyor system
Technical Specificati on: Inte nt of Specifications Page 1 of 18
SECTIO N 2
1.0 IN TEN T O F SPECIFICATION S
1.1 This speci f icat ion is intend ed to cover the fo l low ing act iv i t ies and services in respect of a l l
th e equipm ent o f W agon Tipp ler and Con veyor System Package to b e instal led for Na tional
Aluminium Company Limited (NALCO), Captive Power Project located in Angul of Or issa
Stat e in Ind ia.
(a .) The broad scope o f w ork covers the fo l low ing:i. Detai led design and engineer ing of a l l th e equipm ent and equ ipm ent system(s).
ii . Com ple te m anufacture inc lud ing shop test ing / type test ing .
iii. Providing engineer ing data, drawings, Commissioning procedures and O & M
m anuals, etc. for t he Ow ner ’s review , app roval and record s.
iv . Packing and t ranspor t a t ion f rom the m anufacturer ’s wo rks to s ite .
v . Receipt , unloading, sto rage, preservation and con servation o f equipm ent at si te.
vi . Fabr icat ion, p re-assemb ly, (i f any), erect ion, t est in g and satisfacto ry operat ion o f a l l
th e equipm ent including successful com plet ion of faci l i t ies.
vi i . All associated civil , stru ctu ral and electr ical w orks.
vi i i .
Com m issioning and com plet ion of faci li t ies and Perform ance Guarante e Tests.ix . Furn ishing of spares and hand ing over to NALCO stor es.
x. Reconci l iat ion ( i f any) w i th custom aut hor i t ies.
xi . Satisfactory conclusion of th e contract.
(b.) The equipment and services to be furnished and instal led as required in th is Technical
Speci f icat ion shal l a lso meet a l l the requirements as stated in other sect ions of b id
documents which shal l be considered as a part of th is technical speci f icat ion as bound
he rew i th .
(c.) The Contractor shall be responsible for pro vid ing al l m ater ia ls, equipm ent and services,speci f ied or o ther w ise (unless speci f ical ly excluded) wh ich are requ ired to fu l f i l l the int ent
o f ensur ing operab i l i ty and the re l iab i l i ty o f the comple te system covered under th is
speci f icat ion.
(d.) I t is no t t he int ent t o specify com pletely herein, a l l aspects of design and construct ion o f
equipment. Nevertheless, the equipment shal l conform in a l l respects to h igh standards of
engineer ing, design and workmanship and shal l be capable of performing in continuous
Technical Specificati on: Inte nt of Specifications Page 2 of 18
(e.) Whenever a mater ia l or ar t ic le is speci f ied or descr ibed by the name of a part icular brand,
manufacturer or trade mark, the speci f ic i tem shal l be understood as establ ishing type,
funct ion and qual i ty desired. Other manufacturer ’s products may also be considered providedsuf f ic ien t in fo rm at ion is fu rn ished so as to enab le the Ow ner to de term ine tha t th e products
are equ iva len t o r super io r t o th ose nam ed.
( f .) Bidder is requested to careful ly examine and understand the speci f icat ions and seek
clar i f icat ions, i f required, to ensure that they have understood the speci f icat ions. Such
clar i f icat ions shou ld reach Ow ner at least 15 days befo re the scheduled date o f th e opening of
the bids. The Bidder ’s offer should not carry any sect ions l ike clar i f icat ions, interpretat ions
and/ or assum pt ion s.
(g.) I f the Bidder feels that , in h is opin ion, certa in featur es brought out in h is of fer are super ior t owhat has been speci f ied, those may be highl ighted separately. The Bidder may also make
alternative offers provided such offers are super ior in h is opinion. In which case, adequate
techn ical info rmat ion, operat ing feed back, etc. shal l be enclosed w ith t he of fer , to enable the
Owner to assess the super ior i ty and rel iabi l i ty of the al ternatives offered. In case of each
al ternative offer , i ts impl icat ions on the performance, guaranteed eff ic iency, auxi l iary power
consump tion e tc. shal l be clear ly brought o ut for the Ow ner t o m ake an ov eral l assessm ent . In
any case, the base offer shal l necessar i ly be in l ine w ith t he bidd ing docum ents/ specif icat ions.
Under no circumstances the equipment / system speci f icat ion in Technical Speci f icat ion shal l
be brought ou t as a l te rnat ive o f fe r .
(h .) Any dev iat ion or var ia t ion f rom the scope, requ i rement and/ or in t en t o f th is spec i f ica t ion sha ll
be clear ly def ined b y th e Bidder in Deviat ion Schedules of " Bid Propo sal Sheets" i r respective o f
the fact that such deviat ions/ var iat ions may be standard pract ice or a possib le interpretat ion
of the speci f icat ion by the Bidder. Except for those deviat ions/ var iat ions covered under
Devia t ion Schedu les, wh ich are accepted b y the Ow ner be fore the aw ard o f the Contr act , it w i l l
be the responsib i l i ty o f the B idder to fu l ly meet the in ten t and the requ i rements o f the
specif icat ion w i th in t he quot ed pr ice . No o ther dev iat ion what soever f rom th is spec if ica t ion ,
except fo r the dec lared dev ia t ions submi t ted by the B idder wi th h is p roposa l under
“ Deviat ions” shal l be considered. Bids not com plying with th is requ iremen t shal l be treat ed as
non- responsive and h ence liab le fo r re ject ion . The in terpr e ta t ion o f t he Ow ner in respect o f
the scope, detai ls and services to be performed by the Bidder shal l be binding unless
specif ical ly c lar i f ied o therw ise by t he Ow ner in w r i t ing before the Award o f th e Contract .
( i .) Before subm itt in g his b id, the Bidd er shou ld inspect and exam ine the si te and i ts surr ound ings
and should sat isfy h imself as to t he natu re of th e ground and sub soi l , the quant i t ies and nat ure
of w ork, m ater ia ls necessary for com plet ion o f th e wo rk and th eir avai labi l i ty, means of access
to si te and in general shal l h imsel f obt ain al l necessary info rm ation as to r isks, cont ingencies
and other ci rcumstances which may inf luence or affect h is offer . No consequent extra cla ims
on any misunderstanding or otherwise shal l be al lowed by the Owner. The contractor shal l ,
Technical Specificati on: Inte nt of Specifications Page 3 of 18
pr io r t o com m encem ent o f design wo rk, car ry ou t the Geo- techn ical invest iga t ion in t he area
proposed fo r deve lopment o f wagon t ipp le r and conveyor system package. The number o f
bore ho les sha l l be dec ided b y th e contractor t o ensure adequate data t o car ry ou t the d esignand guaranteeing t he instal lat ion . The cost of such Geo-technical invest igat ion is deem ed to be
inc luded in the b id subm i t ted by th e cont ractor .
( j . ) The sizes of var ious bui ld ings/conveyor gal ler ies indicated in the tender drawings and the
parameters of equipment indicated in var ious sect ions of technical speci f icat ions are the
minimum requirements of the Owner. Any increase in these sizes or the parameters, i f
requ i red to meet the system/main tenance/opera t iona l requ i rement sha l l be supp l ied by the
contractor w i thout any ext ra cost imp l ica t ion to t he Owner .
(k .) The works under the scope o f th is contract a re t o be executed in an op era t ing pow er s tat ion .The contractor shal l take al l necessary precautions to protect a l l the exist ing equipment,
structures, faci l i t ies and bui ld ings etc. from damage. In case any damage occurs due to the
activ i t ies of t he cont ractor on account o f negl igence, ignorance, accidental or any o th er reason
w hatsoever , the damage sha l l be im m ediate ly made good by t he contractor a t h is ow n cost to
th e sat isfact ion o f t he Ow ner. The cont ractor shal l a lso t ake al l necessary safety m easures, at
h is own cost , to avo id any harm or in ju ry to h is workers and s ta f f f rom the equ ipment and
fac il it ies o f the pow er p lan t .
( l .) Cont ractor sho uld note that t he exist ing ra i l l ines w ith in th e plant area are operat ional w i th ra i l
t raf f ic of coal and l iquid f uel rakes. Cont ractor shal l take al l precaut ions to en sure t he safety ofexist ing r a i l t racks and o ther associated faci l i t ies as wel l as th e safety of h is men , mat er ia l and
equ ipment f rom the opera t ing ra il t ra f f i c . The contractor sha l l p lan and make a l l a r rangements
to ensure t ha t d isrupt ion to the ex ist ing ra i l t ra f f i c is min imum and sha l l fo l low the inst ruct ions
of the Owner in th is regard. Further, contractor shal l p lan and coordinate al l h is act iv i t ies
consider ing restr ict ion s, i f any, on free access to h is w ork areas due to th e ra i l t raff ic.
(m.) Aft er award o f w ork and , befor e f inal is ing his layout especial ly the layout / levels of con veyors,
cable / p ipe routes and other services, the contractor shal l carry out a si te survey to identi fy
the location & detai ls of exist ing faci l i t ies that may inter fere wi th h is proposed faci l i t ies. The
contractor shal l sui tably modify h is layout / levels to prevent d islocation of exist ing faci l i t ies
and any cost / t ime impl icat ion ar is ing out of such modif icat ions shal l be to h is account.
Contractor shal l a lso be responsible to determine and obtain the necessary detai ls at s i te as
requ ired for int er facing and int erconnection w ith th e exist ing system / faci l it ies.
(n) I f dur ing th e executio n of wo rks i t is foun d that th ere is int er ference with t he exist ing facil i t ies
/ st ru ct u res, t h e co n t rac t or sha ll revi se h is d es ign / d et ai le d d raw in gs t o clea r t he in t er fe rence
and shal l provide al l necessary m easures for the safety o f exist ing struct ures. No cla im in term s
of cost or re laxation in t ime shal l be enterta ined for any redesign, rework and for safety
m easures prov ided. I f a t any s tage o f wo rk, any d ism ant l ing or m od i f ica t ion or re locat ion o f
Technical Specificati on: Inte nt of Specifications Page 5 of 18
Coal received a t the t ipp le r hopper w ou ld b e t ranspor ted by be l t conveyors and in tegrated t o
ex ist ing system for feed ing the ex ist ing and th e new stockp i les under deve lopment .
2.1 BRIEF DESCRIPTION OF PROPOSED W AGO N TIPPLER AN D CON VEYOR PACKAGE
( i ) Indian Rai lway rakes consist ing of Box-N wagons shal l transport coal to the power plant.
These Box-N wagons are proposed to be unloaded in underground RCC hopper by means of a
Rota side Wagon Tippler . Wagon t ippler hopper shal l have a holding capaci ty of minimum 2
wagons loads of coal i .e. 120 Tonnes. One Rota side wagon t ippler (WT-1) is to be ut i l ised for
un loading of IR coal rake. A Side arm charger is envisaged f or p lacem ent of loaded w agon on the
t ipp ler t ab le & re t r ieval o f emp ty wagon f rom the t ipp le r tab le a f te r t ipp l ing . Clear access sha l l
be prov ided fo r movement o f pay loaders on the hopper s ide o f bo th Wagon t ipp le r . Wagon
tipp ler hopp er grat ing is to b e posi t ioned and designed accord ingly.
( i i ) Apron feeder is proposed under the Wagon t ippler for extract ing coal from the Wagon
t ipp ler hopp er and feed in to the s izer w h ich in tu rn d ischarges crushed coa l on t o the pr oposed
receiving conveyor RC-1. Conveyor RC-1 wi l l t ransfer the coal to conveyor RC-2 at the new
tran sfer to w er TP-1. Conveyor RC-2 shall feed coal on to exist in g Con veyor BC-103/BC-115 at th e
exist ing junct ion hou se (JH-1). The rated capaci ty o f a l l th e conveyor s in th is package shal l be
1200 TPH.
(i i i) The existing CHP control and monitoring system is PLC based. It is proposed to provide an
independent PLC based contro l fo r smooth , e f f i c ien t & t roub le f ree opera t ions o f WagonTippler , s izer and conveyor system package. The control and monitor ing system for bel t
conveyors covered under th is Package shal l be integrated w ith t he exist ing cont rol system such
that th e operat ion of exist ing CHP is not h amp ered. Necessary inter locks and soft war e changes
in t he exist ing PLC logic are also en visaged in th is package.
3.0 SCOPE OF W ORK
3.1.1 The scope of Wa gon Tippler and Conveyo r System Package to be furn ished, erected and
com m issioned u nd er th is speci f icat ion shall be as detai led h ereinafter . The Cont ractor shal l be
ful ly responsible for system and detai led design, engineer ing, manufacture, shop fabr icat ion,
assembly, test ing and inspection at manufacturer ’s works, packing, d ispatch, transportat ion,
tran si t in surance, custom clearance etc. as appl icable, del ivery t o si te, un loading, handl ing and
storage at si te, insurance dur ing storage, construct ion, erect io n, including erect ion supervision,
test ing, inspection, commissioning and handing over to Owner and Guarantee test ing including
all associated elect rical, civi l & stru ctu ral w or ks as specified , unless sp ecifically exclud ed as per
Section -Term inal Poin t s & Exclusions.
3.1.2 The scope of th e contracto r shal l be deemed to include al l such i tem s wh ich al thou gh are not
spec if ica lly m ent ioned in t he b id docum ents and/o r in Contractor ’s p ropo sa l bu t a re needed t o
Technical Specificati on: Inte nt of Specifications Page 6 of 18
make the system complete in a l l respects for i ts safe, re l iable, eff ic ient and trouble free
op erat ion and th e sam e shal l be furn ished and erected un less otherw ise specif ically excluded in
th is document. The general descr ipt ion of the proposed system and the broad scope of workunder the spec if ica t ion sha ll inc lude bu t no t b e l imi ted to as deta iled be low.
3.1.3 An und erground RCC W agon Tipp ler Hopper, m achinery hatches w ith wagon t ippler hopp er,
assoc iated und erground t unne l , t ransfer po in t and pent house comp le te wi t h c iv i l, st ru ctura l
and electr ical works for Wagon Tippler hopper and machinery hatches, steel grat ing over
hopper port ion, removable chequered plate covers over openings in machinery hatches for
handl ing underground equipment, equipment handl ing faci l i t ies for apron feeder and sizer uni t
inside be low w agon t ipp le r hopper inc lud ing the s t ructu ra l stee l shed w i th E .O.T crane over th e
WT-1 and other equipment/systems such as Dust Suppression system, venti lat ion system,
drainage system etc. as speci f ied elsewhere in the speci f icat ion. However, the track work isexcluded from Contractor ’s scope however ra i ls over t ippler table and the track for Side Arm
Charger are included in Contracto r ’s scope.
3.1.4 One (1) no. Rotaside W agon Tippler comp lete w i th clampin g arrangemen ts, a l l str uctur al
members, t ippler p latform, t ippl ing mechanism, t ippler dr ive along with necessary controls,
associat ed electr icals, civi l / stru ctu ral w or ks and accesso ries.
3.1.5 Side arm charger associated with the Wagon Tippler comp lete w i th travel ra i ls, dr ive equ ipm ent
along w ith necessary con tro ls, associated electr icals, c iv i l/ struct ural w ork s & accessor ies.
3.1.6 One (1) no . Apron f eeder comp lete w i th dr ives, al l m echanical , e lectr ical accessor ies &
suppor t ing s t ructure e tc .
3.1.7 One sizer uni t comp lete wi t h dr ives and al l m echanical e lectr ical system and concluding the
suppor t ing s t ructure e tc .
3.1.8 Receiving Belt Con veyors RC-1 com plete wi t h conveyor supp ort ing stru ctures, shor t suppo rts,
str ingers, deck plate, seal p late, conveyor fo undat ions, dr ive m oto rs, dr ive uni ts, pul leys, id lers,
gravi ty take ups, take up structure upto ground level , take-up platforms at intermediate level ,
internal and external bel t c leaners, pul l chord switches, bel t sway and zero speed switches,
electro-hydrau l ic t hru ster brakes, a l l e lectr icals etc. including RCC tunn el fo r receiving Conveyor
RC-1 and un dergroun d t unnel po rt ion up to p ent ho use of Conveyor RC-1 with a l l c iv i l, str uctu ral
and archi tectural works for conveyor gal lery, gal lery support ing trest les and their associated
foundat ions.
3 .1 .9 A new pent hou se a long wi th over g round st ructu res, fo r conveyor Rc-1 com ple te wi th a l l c iv i l
structural , archi tectural and electr ical works including chutes, monorai ls, hoists/chain pul ley
blocks, hoist m aintenance p latform s, RCC/ steel f loor s, extern al sta ircases, hand rai ls etc.
Technical Specificati on: Inte nt of Specifications Page 8 of 18
3.1.20 M on orai ls and electr ical ly operat ed hoist b locks as w el l as hand op erated chain pul ley blocks for
servicing/ instal lat ion/easy replacement of dr ive machinery, d i f ferent types of pul leys for a l l
conveyors, GTU and o th er equ ipm ent .
3.1.21 Al l bui ld ings in contractor ’s scope shal l be complete wi th a l l e lectr ical , c iv i l , structural ,
archi tectural works, cable trenches, f i re safety wal ls, foundation / fencing / earth ing for
tran sform ers. Al l cables / du ct banks, trenches, cable trest les shall be com plete w i th associated
civil / structu ral wo rk and necessary civi l found ations.
3.1.22 Drainage of W agon Tippler h opp ers, tun nels, conveyor gal ler ies, TPs, upt o n earest exist in g CHP
drain al l civ i l & struct ural wo rks.
3.1.23 Al l equ ipm ent / f i t t ings, support ing stru cture, a long w ith insert p lates, bol t s, accessor ies, M Ssleeves, base plates, grout ing as m ay be requ ired and prop er a l ignm ent etc.
3.1.24 A comp lete set of a l l special to ols and tackles, which are necessary or convenient fo r erect ion,
comm ission ing and o verhau l ing o f any equ ipm ent , covered under the scope.
3.1.25 First f i l l of a l l con sum ables e.g.; o i ls and lub r icants for on e year to ppings requirem ent s.
3.1.26 Preservative shop coating, f inal paint ing of a ll structu res and equipm ent und er the scope.
3.1.27 Fire hydrant system along with FDA system should also be th e scope of th e tender er.
3.2 Electr ical System / Equ ipm ent
3.2.1 Unless speci f ical ly excluded, cont ractor ’s scope of w ork shal l include al l e lectr ical w orks as
required for putt ing into successful operat ion of the Wagon Tipplers & Associated Conveyors
covered und er th is speci f icat ion.
3.2 .2 LT SW ITCHGEAR
415V Switchgear/motor control centers distr ibut ion boards, AC & DC fuse boards, local
emergency stop push but t on s ta t ions fo r a l l d r ives and local m oto r s ta r te rs as requ i red f o r p lan t
and equ ipm ent .
3.2.3 M OTORS
M ot ors along w ith coup l ings and coupl ing guards for a l l rotat ing auxi l iar ies are covered und er
th is package. Al l m ot ors shal l be w ith cable glands & lugs.
3.2.4 CABLES
HT & LT Pow er cables, contro l cables, Instru m entat ion cables and an y special cables required for
connection between equipment / devices in Contractor ’s scope and also cables between
Own er ’s equ ipment and Cont ractor 's equ ipm ent .
Technical Specificati on: Inte nt of Specifications Page 9 of 18
3.2 .5 CABLING , EARTHIN G AND LIGHTNIN G PROTECTION
(a) Al l cabl ing with cable accessor ies, cable trays with support ing structure, terminations and jo in t in g kit s, t r en ch es, over h ead t rest le , d uct ban ks e tc. as req u ir ed f o r t h e cab le s t o b e supp lied
by the Contractor .
(b ) Ground ing and l igh tn ing pro tect ion fo r t he p lan t and equ ipment under Contractor ’s scope
a long wi th i ts in te rconnect ion to the nearest Ow ner ’s ear th gr id a t tw o po in ts.
3.2.6 ILLUM INATION SYSTEM
Comple te i l luminat ion system as requ i red fo r comple te in te rna l and externa l l igh t ing o f
associated p lant , equipm ent and bu i ld ings covered und er Cont ractor ’s scope including 2 Nos. of
Light ing M asts for area l ight ing in W .T. area.
3.2.7 CON TROL SYSTEM
An ind ependent Cont rol desk, PLC panels, I /O racks, UPS, batter y & batt ery chargers etc. for th e
contro l o f W agon Tipp lers and o ther equ ipm ent .
One (1) No. control bui ld ing to be located near WT-1 . This bui ld ing shal l have two f loors i .e.
ground & f i rst f loors. The f i rst f loor of control room shal l house PLC panels, control desks for
operat ion of WT-1. One off ice room (5m x 5m) at the f i rst f loor. There shal l be a projected
viewing balcony at a sui table location to have clear view of the Wagon Tipplers dur ingop erat ion. The ground f loor shal l hou se t he M CC, DBS, Batt ery DBS etc.
3.3 CIVIL W ORKS
3.3.1 The w ork to be perfo rm ed under th is speci f icat ion consists of provid ing al l labor, mat er ia ls,
construct ion equipment, tools and plant, scaffo ld ing, suppl ies, transportat ion, a l l incidental
i tem s not show n o r speci f ied, but reasonably im pl ied or n ecessary for successful complet ion of
the work including Contractor ’s supervision and in str ict accordance with the drawings and
specif icat ions. The nat ure of w ork shal l general ly involve earthw ork in excavation including very
deep underground excavation, de-water ing, shor ing and strutt ing, sheet p i l ing, back f i l l ing
around completed structures and pl inth protect ion, area paving, d isposal of surplus excavated
mater ia ls, p i l ing, concret ing including reinforcement and form work, br ick work, fabr icat ion and
erect ion o f structu ral / m iscel laneous steel w ork s, inserts, archi tectural i tem s & f in ishes such as
plaster ing, paint ing, f loor ing, doors, wind ow s & venti lato rs, glass and glazing, ro l l ing shut ters
etc., permanently colour coated prof i led steel sheeting, anchor bol ts, R. C. C. trenches with
covers, drainage, damp proo fing, w ater proo fing and oth er ancil lary item s.
3.3.2 The w ork shal l have to be carr ied out both b elow and above ground level and shal l be involving,
Technical Specificati on: Inte nt of Specifications Page 10 of 18
steel fr am es, b rick w alls, stair s, tr en ches, p its, access roads, culvert s, conveyer galleries, trestles,
penthouses, Wagon t ippler hopper, underground tunnels, transfer points, f in ishes, complete
archi tectu ral aspects, drainage and al l oth er civi l, archi tectu ral and structu ral w orks associatedw ith th e com plet e Wagon Tippler and conveyor system Package.
3.3.3 Scope of w ork shal l a lso include dism ant l ing and m odif icat ions of th e exist ing
st ructures/ faci li t ies, w h ich may be requ i red to fac il ita te , in te r connect ion betw een th e ex ist ing
and th e new st ructures or fac i li t ies and m aking good t he d ismant led /m odi f ied s t ructures.
4.0 TERM INAL POINTS
Term ina l po in t fo r Wagon T ipp ler and conveyor system com m ences f rom w agon t ipp le r complex
upto feeding points at conveyors BC-103 & BC-115, in Junction House (JH-1) including themodif icat ion necessary to the Junction House. With in these terminal points, a l l equipment and
services, civ i l , structural and archi tectural works, e lectr ical d istr ibut ion, p ip ing network etc. as
requ i red fo r wagon t ipp le r and conveyor system package w i ll be fu rn ished and erected b y th e
cont ractor unless speci f ical ly excluded.
4.1 Con tracto r 's Scope responsibi l i t ies shal l include but not be l imi ted to th e fo l low ing:
4 .1 .1 W herever Contr actor is perm i t ted by Ow ner to take suppor t f rom any o f the Ow ner ’s
Structures, the Contractor shal l ensure that no damage is done, to the Owner ’s Structures
including Paint ing th ereof. In case of any dam age to th e Owne rs Struct ure and/ or Paint ing, th en
the Cont ractor sha ll rect i fy the sam e to t he comp le te sa t isfact ion o f t he Ow ner .
4.1.2 The con tracto r shal l carry out t he redesign of JH-1 and shal l ensure that th e proposedm odif icat ions are adequate to suppo rt t he d ischarge point o f the con veyor RC-2 as w el l .
4.1.3 Regarding erect ion of transfer point on exist ing junct io n house-1, cont ractor shal l ensure that
opening on exist ing bui ld ing and erect ion of conveyor chutes/skir ts & platform are done in a
m anner to m inim ize shu t do w n of exist ing conv. BC-103 & BC-115. As work is to b e executed in
opera t ing pro ject , ext ra care must be taken by the Contractor .
4.1.4 W ater supp ly connection s for dust supp ression, service w ater system & cool ing w ater shal l be
provided by the Owner, detai ls of which are given elsewhere in the speci f icat ion. Further
net w ork of p ip ing including al l com pressors, pum ps, tanks, necessary accessor ies, suppo rts and
fi t t ings etc. for d istr ib ut ion of w ater fo r dust supp ression and service wat er system in al l t ransfer
po in ts , contro l room s, M CC rooms, to i lets , M ach inery ha tches o f th e W agon t ipp le r e tc . sha l l be
under th e scope o f the contractor .
4.1.5 Road l ight ing in w agon t ipp ler area, for th e roads, is included in th e scop e of Con tracto r.
Technical Specificati on: Inte nt of Specifications Page 11 of 18
4.2 EXCLUSIONS
4.2.1 Supp ly, laying and f ix ing of ra i l t r ack for th e inhaul and out haul sid ing is excluded for th e scopeof th is Cont ract. Howe ver, sup ply, laying and f ix ing of r a i l over W agon Tippler table and fo r side
arm charger is included in t he scope o f th is Con tract.
4.2.2 Si te leveling and access roads are excluded from the scope of t h is Con tract. How ever si te
clearance i .e. rem oval of vegetat ion including bushes and t rees etc. shal l be t he r espon sibi l ity of
the Cont ractor .
5.0 SYSTEM DESIGN BASIS
5.1 The rated capaci ty of the Conveyor s shal l be 1200 TPH. The design capaci ty of th e conveyorsshall be 13 20 TPH. The m echanical and str uctural / c iv i l system shal l be d esigned fo r 1320 TPH
capacity and round the c lock opera t ion w i th bo th t he s t reams opera t ing s im ul taneously .
5.2 Fol low ing shal l be consider ed w hi le designing the Conveyo rs :
a. The Coal del ivered t o th e pow er stat ion shal l be of size 300 m m & below . How ever occasional ly
coal of h igher lump size m ay also be encoun ter ed.
b . HGI o f the Coa l sha l l be betw een 44 to 65 . Normal ly mo isture content in coa l w i l l vary be tw een
6% to 10%. How ever for design pu rposes, moistu re cont ent o f 10% shal l be considered.
c. The coal “ as received” shal l contain varying percentage of f ines. Coal w i th such f ines may t end
to fo rm adhesive lumps, par t icu lar ly dur ing mon soon w hen sur face m oisture is a t i ts m aximu m
value.
d . The sizing and select ion of the vi ta l equipment viz. apron feeder and sizer covered under the
system shal l be based on th e above character ist ic of coal and op erat ing condi t ion s. Cont ractor
shal l ensure that equipment/ system eff ic iency shal l not be effected part icular ly dur ing
m onsoon wh en sur face mois ture is a t i ts m axim um va lue.
5.3 For the pu rpose of volumet r ic com put at ion , the bu lk densi ty of th e coal shal l be taken as 800
kg/m 3. There fore fo r ca lcu la t ion o f be l t conveyor capacity , fo r th e i r d r ives & dr ive m otor s kW
requ iremen t, and sizing (volum e calculat ions) of chu te, hopp ers etc. th e above bulk densi ty shall
be con sidered. For a l l oth er pu rposes viz. fo r stresses/ load on stru ctures, loading on sizer and
Apron Feeder tables, siz ing of actuators for f lap gates, calculat ions of p lugged chute/ hopper
loads etc. th e bulk densi ty of th e coal shall be taken as 1100 kg/ m 3.
5.4 Coal Flow path s
5.4.1 For th e pu rpose of conduct ing guarant ee test coal , th e fo l low ing f low path w ou ld be assessed.
Technical Specificati on: Inte nt of Specifications Page 13 of 18
7.2.1 Flow Path Capacity
Flow path capaci ty inc lud ing the in te rm edia te equ ipment fo r conveyor s t reams to be tested fo r1200 TPH
7.2.2 Equ ipm ent Capacity
Capaci ty of ind ividual equipm ent shal l be t ested separately:
( i ) Each W agon Tippler : 20 t ips/ hou r (Guarant eed)
( i i) Each Apron feeder : 1200 TPH (Guaranteed)
(i i i) Sizer un it : 120 0 TPH (Guarant eed)
7.2.3 Cont ractor shal l a lso dem onstrat e that a l l in ter m ediate equipm ents viz. Gates, Dustsuppression, Vent i lat ion System et c. can perfo rm as per speci f icat ion and design requ iremen t.
7 .2 .4 Per form ance and guarantee requ i rem ent o f var ious o ther equ ipm ents have been e labora ted
elsewhere.
8.0 PERFORM AN CE & GUARA NTEE TEST PROCEDU RE
In accordance with GTR the plant shal l be subjected to performance and Guarantee Tests on
successful complet ion of tr ia l operat ions. Further, the performance and Guarantee Tests shal l
be conducted as per the gu ide l ine p rocedure ind ica ted e lsewh ere . However , de ta i led procedure
shal l be submitted by vendor as per the guidel ines for Owner 's approval . The P&G Testprocedure sha ll be subm i t ted as per fo rmat a t tached in t he speci f ica t ion .
8.1 Liquidat ed Damages for Sho rtfa l l in Perform ance
Shou ld t he resu l ts o f t he per fo rm ance and guarantee t ests show tha t the equ ipm ents / system
have fa i led to meet the guaranteed parameters, the Contractor shal l carry out modif icat ions, i f
cons idered n ecessary, w i th in 90 days o f the not i f i ca t ion by Owner .
I f the equ ipment fa i ls to meet the guarantee parameters a t the end o f the above spec i f ied
per iod o f 90 days, Ow ner m ay at h is d iscret ion, re ject t he equipm ent o r accept i t a fter assessing
th e l iquidated dam ages at rat es speci f ied herein, to be payable by the Cont ractor.
8.2 The fo l low ing equipm ents/ stream s shal l be subject ed to perfo rm ance and guarantee test in l ine
w i th th e spec if ica t ion to prove the per fo r mance guarantee fo r a l l in te rm edia te equ ipm ent .
Liquidat ed Damages to ward s shor tfa l l in guarant eed perfo rm ance shal l be impo sed @ 1% of th e
ord er value l imi t ing to 10% against fo l low ing param eters.
Technical Specificati on: Inte nt of Specifications Page 15 of 18
11.0 SPARES
11.1 GENERAL
The Cont ractor shal l include in h is scope of supp ly a l l th e necessary M andato ry spares, star t up
and commissioning spares and recommended spares and indicates these in the re levant
schedules of the Bid Form and Pr ice Schedules. The general requirements perta in ing to the
supply of th ese spares have been descr ibed in t he fo l low ing paras.
11.2 M AN DATO RY SPARES
11.2.1 The l ist of m andato ry spares considered essent ia l by th e Own er is included in th is speci f icat ion.
The Bidder shal l ind icate t he pr ices for each and every i tem (except f or i t em s not app l icable tothe Bidders design) in the ‘Schedule of mandatory Spares’ whether or not he considers i t
necessary for t he Own er to h ave such spares. If th e Bidder fa i ls to com ply w i th t he above or fa i ls
to quo te th e pr ice of any spare i tem , the cost o f such spares shal l be deemed to be includ ed in
the bid pr ice unless the bidder speci f ies "not appl icable" for the type of equipment/system
offered by him. However dur ing execution i f such spares are found to be appl icable, the
Contractor sha l l supp ly them wi thout ext ra cost to the Owner . The B idder sha l l fu rn ish the
popu la t ion per un i t o f each i tem in the r e levant Schedu les. W henever the quant i ty is m ent ioned
in “ sets” the B idder has to g ive the i tem deta i ls and pr ices o f each i tem.
11.2.2 W henever th e quanti t y is indicated as a percentage, i t shal l m ean percentage of to ta l populat ionof that i tem in the Package, unless speci f ied otherwise, and the fract ion wi l l be rounded off to
the n ext h igher who le number . W herever the requ i rement has been spec i f ied as a ‘set ’ i t w i ll
inc lude the to ta l requ i rement o f the i tem for a un i t , modu le or the s ta t ion or as spec i f ied .
Where i t i s no t spec i f ied a ‘se t ’ i t w i l l inc lude the to ta l requ i rement o f the i tem for a un i t ,
module or the stat ion or as speci f ied. Where i t is not speci f ied a ‘set ’ would mean the
requ i rement fo r the sing le equ ipment / system as the case may be. A lso o ne se t fo r the par t icu la r
equ ipment . e .g . ‘set ’ o f bear ings fo r a pump wou ld include the to ta l num ber o f bear ings in a
pum p. A lso the ‘se t ’ wou ld inc lude a l l com ponents requ i red to rep lace the i tem ; fo r example , a
set of b ear ings shal l include al l hardw are norm al ly required w hi le replacing the bear ings.
11.2.3 The Ow ner reserves the r igh t to buy any or a l l the m andatory spare par ts .
11.2.4 The pr ices of m andato ry spares indicated by t he Bidder in the Pr ice Schedules shal l be used for
bid evaluation pur poses.
11.2.5 All mandatory spares shal l be del ivered at si te at least two months before scheduled date of
in i t ia l operat ion. However, spares shal l not be dispatched before dispatch of corresponding
Technical Specificati on: Instructions To The Bidders Page 2 of 12
param eter g iven in Technical Speci f icat ion s the sam e shal l be clear ly ment ioned in th e deviat ion
l ist , w i th reasons th ereof.
1.1.9 I f th e Bidder feels that any info rm ation/ data descr ibed in the technical speci f icat ion needs to be
m odif ied , he shal l indicate the same specif ical ly and subm it an al ternat ive propo sal , on the basis
o f the d esign data , tha t he cons iders su i tab le and capab le o f m eet ing the requ i rem ent o f t h is
speci f icat ion.
1.1.10 Al l th e mat er ia ls used and equipm ent suppl ied shal l be new and th e best of heir k ind and shal l
comply wi th the s ta tu tory requ i rements o f the Govt . o f Or issa , Govt . o f Ind ia and the la test
revision of the Indian Standards/ Indian Electr ic i ty Rules. Where the equipment/ mater ia l
supp lied is no t accord ing to Ind ian Standards or regu la t ions to wh ich the equ ipm ent / m ater ia l
conform , the B idder sha ll subm i t re levant d ocument a long wi th t he B id .
1.1.11 The Bidder shal l v is it the p lant / s ite, and sat isfy h im self fu l ly about th e exist ing plant / s ite
cond i t ions etc. The successful Bidder shal l bear fu l l responsibi l ity for inferences and conclusion s
as to the nature and cond i t ions under wh ich the work is to be executed, inc lud ing e f fect o f
cl im ate, ra infa l l etc. Fai lure to do so shal l no t absolve th e Bidder o f h is respon sibi l it ies about th e
proper execution of the job. No cla im for extra payments due to any special s i te condi t ions and
ignorance about th e si te condi t ion s shal l be considered after acceptance of h is Bid. For t he si te
v isi t , the Bidder sha l l contact t he Purchaser and t ake pr io r appo in tm ent f ro m them .
1.1.12 The drawings of the exist ing coal handl ing plant, avai lable wi th the Purchaser, can be madeavai lable to the successful Bidder for reference. However, for the areas of the plant for which
draw ings are no t avai lable, the Bidder shal l make si te m easurem ents and w ork accordingly.
1.1.13 The Bidder as far as pract icable ensure th at m ajor equipm ent s are brou ght to si te in pre
assembled condi t ion to minimize si te work and to achieve an ear ly commissioning of the
equipm ent aft er d el ivery. Si te w elding shal l be avo ided as far as po ssib le. The Successful Bidder
befo re pro ceeding w ith de sign d etai ls shal l sat isfy h im self abou t t he si te condi t io n so as to avoid
any di f f icul ty in erect ion ar ising out o f design.
1.1.14 The equipm ent shal l be inspected du r ing di f feren t stages of i ts m anufactur e (star t ing from raw
m ater ial t i l l the comple t ion o f m anufacture) by the Purchaser / h is au thor ized representa t ive a t
th e Bidder 's or h is sub Successful Bidder 's wor ks as per t he inspection p rocedure m utu al ly agreed
between the Purchaser or h is author ized representat ive and the successful Bidder. Inspection
shal l be regarded as a check up and shal l be in no way binding on the Purchaser. However,
general terms and condi t ions of inspection and test ing is indicated in the subsequent chapter of
Technical Specificati on: Instructions To The Bidders Page 5 of 12
1.1.33 Subject t o availabi li ty and at th e request of t he successful Bidder, water fo r construct ion purpo se
wi l l be made avai lable by the Purchaser at one mutual ly agreed point at s i te. The successfulB idder sha ll m ake h is ow n ar rangement fo r any fu r th er d ist r ibu t ion a t h is ow n cost . Water supp ly
shall be f ree of cost and shal l be p rovided a s speci f ied un der clause no. 54.13 b) o f t he GCC.
1.1.34 Pow er Supp ly
Subject to avai labi l i ty and at the request of the successful Bidder, Electr ic Power wi l l be made
ava ilab le a t one po in t on ly a t a d istance not m ore t han 500 met ers away f rom the Contr actor ’s
premises. The power wi l l be suppl ied at 400/440 Vol t and shal l be metered and charged at the
rat e as speci f ied in the GCC. The successful Bidder shou ld have suff ic ient n um ber & capaci ty o f
DG sets to m eet th e emergency pow er requ i rements in the event o f f a i lu re in pow er supp ly .
1.1.35 Civi l and stru ctural steel w orks
The supp ly of con veyor gal ler ies, trest les, Junction tow ers, bui ld ings & civi l wo rk are in t he scope
of th is tender, including the design of Civi l & Structural , shal l be with in the scope of successful
b idder .
1.1.36 Fire hydrant system
The Bidder shal l include in h is scope extension & rerouting of f i re hydrant system to the wagontipp ler & conveyor system . The hyd rant l ine shou ld b e la id as per IS specif icat ion.
1.1.37 Exclusions: Fol low ing i tem s are exclud ed from t he scope of w ork
1. Rai lway t rack system .
1.2 ERECTION
1.2.1 The successful Bidder shal l be respon sible and perform t he fo l lowing with respect to the erect ion
of th e Plant and suppl ies.
1.2.2 The scope of wo rk of the successful Bidder shal l be com plete erect ion of the Plant and Equipm ent
etc. as specified in the Technical Specification. The Bidder shall make all arrangements to deliver
the equ ipment a t Purchaser ’s s to res / s i te by wagons / t ruck / t ra i le rs , bu i ld h is own s tores
(covered, uncovered and air -condi t ioned, i f necessary) for the proper storage of equipment,
m ain ta in t he s tores and a l l re la ted docum ents and records, t ranspor t the equ ipm ent to si te fo r
erect ion purpose and take an Erect ion- cum- Storage insurance pol icy cover ing al l the r isks
including th ird par ty l iabi l i ty fo r a l l suppl ies as wel l as hum an l i fe. Al l secur i ty arrangemen ts also
Technical Specificati on: Instructions To The Bidders Page 6 of 12
shal l be made by the successful Bidder. Space only for stores and si te off ice shal l be made
avai lable to t he Bidder by th e Purchaser.
1.2.3 The successful Bidder shal l take the equipm ent from stor es and transport t he same to erect ionsite.
1.2.4 The successfu l Bidder shall un pack and do visual checking against physical damages to t he
equipm ent / cases, cleanin g of equ ipm ent befo re star t of erect ion. Damage / shortage i f any, wi l l
be repor t ed to the Purchaser / consu l tan t and sha l l be rect i f ied / rep laced exped i t ious ly, f ree o f
charge to Purchaser so as not to upset the erect ion and commissioning schedule. Delay on
account of sett lement of insurance cla ims by the successful Bidder shal l not be considered an
excuse fo r de lay in comple t ion .
1.2.5 The successful Bidd er shal l lay and maint ain proper ly a l l th e tem po rary supp ly l ines in theerect ion si te fo r t em porary pow er and wat er requ i red fo r s to rage and erect ion purposes f rom a
single point to b e provided by t he Purchaser. Dr inking w ater shal l a lso be m ade available at one
central point at s i te. The successful Bidder shal l make his own arrangement for any fur ther
d is t r ibu t ion .
1.2.6 The successful Bidder shall arrange all necessary construct ion m achinery/ equip m ent, too ls &
tackles, instruments, compressors, smal l hand tools, welding equipment, a l l commissioning
instrum ent s, erect ion & service bol ts, nuts, j igs and f ixtu res, w inches, a l ignmen t t ools, precision
leve ls e tc . , Crane/ ho is ts and o ther equ ipment wh ich may be requ i red fo r car ry ing out the
erect ion work eff ic ient ly wi th in the t ime schedule provided herein the speci f icat ion. Unlessotherwise speci f ied, the above construct ion mater ia ls shal l be the property of the successful
Bidd er. How ever Purchaser 's pr io r perm ission shal l be required fo r rem oval of t hese constru ct ion
m ater ia ls fro m t he site. Successful Bidder shal l ensure that prop er docum entat ion is maintained
for such i tem s, wh ich are required to b e carr ied back by successful Bidder after t he com plet ion of
w o r k .
1.2.7 The successful Bidder shal l provide al l tem porary ladders, scaffo ld ing ma ter ia ls, p latform s,
supports and other necessary faci l i t ies required for handl ing, erect ion, test ing and visual
inspection o f suppl ies at th e po int o f instal lat ion and shall a lso p rovide necessary packing plates,
wedges, shims, level l ing screws etc. required for erect ion of equipment and technological
structures.
1.2.8 The successfu l Bidder shall pro vide erect ion con sum ables l ike oxygen and acetylene gas, w eldin g
rod s, solder lugs, o i l , grease, kerosene, cot ton w aste, etc. required for erect ion of eq uipm ent and
Technical Specificati on: Instructions To The Bidders Page 8 of 12
Bid by successful Bidder) and comply wi th such reasonable instruct ions of the Purchaser /
Consul tant in the interest of sat isfactory progress and complet ion of the work according to the
schedule. The successful Bidder shal l work in 3 shi f ts per day basis for meeting the complet iontarget , if requ i red wi th in the contract p r ice .
1.2.20 The successful Bidder shal l organise th e wor k in a manner t hat ot her w ork at site is not im peded
and th e wo rkm en th erein not en dangered and shal l arrange tem porary access at site, i f requir ed
fo r t he e rect i on wo rk .
1.2.21 Successful Bidder shall ret urn t o th e Pur chaser all crat es, packing cases and packing m at erials
excess comm issioning spares, o i l and lubr icants at a p lace designated b y t he Purchaser.
1.2.22 The successful Bidder shall conduct a l l necessary tests / ch ecks dur ing erect ion .
1.2.23 The successful Bidder shal l attend to t he rect i f icat ion o f erect ion def ects, i f any, expedi t iously.
The successful Bidder shall arrange al l test ing instrum ent s for such test ing at si te.
1.2.24 The successful Bidder shal l carry out f inal paint ing of th e Plant & Equipm ent and t echnological
Stru ctures etc. erected as per t he instru ct ions st ipulated in t he Technical Speci f icat ion.
1.2.25 The successful Bidder shal l be respon sible for t ota l com m issioning of th e Plant and equipm ent
including cold tr ia l run and demonstrat ion of Performance Guarantee Test. The Purchaser 's
supervisory and ski l led operat ing personnel shal l , however, be avai lable to work under the
guidance and super vision o f the Bidder . Necessary raw m ater ia ls, auxi l iar ies, ut i l i t ies, e lectr ic i tyand op erat ing personnel shal l be mad e available by th e Purchaser cover ing 3 shi f ts operat io n as
per t he programm e agreed to in advance.
1.2.26 The Successful Bidder shall sup ervise runnin g o f the Plant fo r sat isfactor y, rel iable and regular
operat ion and performance after i ts successful commissioning for establ ishing performance
guarantees.
1.2.27 Electr ical energy and construct io n w ater shal l be supp l ied b y Purchaser to the successful Bidder
dur ing erect ion , a t one po in t .
1.2.28 Al l safety m easures required t o be adopt ed as per th e Stat uto ry Regulat ion s & the Safety Rules of
th e Plant shall be str ict ly fo l low ed by th e successful Bidder dur ing th e execut ion of the Con tract.
The successful Bidder shal l depute safety engineers for str ict ly compl iance of safety ru les &
regulat ions.
1.2.29 The successful Bidder shal l int im ate th e Plant author i t ies in w r i t ing w el l in advance about the
requ i rement o f shut down o f any o f the ex is t ing un i ts / fac i l i t ies fo r in te r connect ion /
incorporat ion of addi t ional faci l i t ies. The shut down per iod shal l be mutual ly d iscussed and
Technical Specificati on: Instructions To The Bidders Page 10 of 12
1.4 OPERATING / PERFORM ANCE PARAM ETERS
All the equipment covered in th is speci f icat ion shal l fu l f i l l the operat ing and performancerequ iremen t covered und er th is Technical Speci f icat ion and indicated in the app roved draw ings.
The successful Bidder shal l study the speci f icat ion and satisfy h imself thoroughly regarding the
w orkab i li ty and su i tab il i ty o f t he equ ipm ent o f fe red by h im . He sha l l take fu l l responsib il ity fo r
the guaranteed and sa t isfactory opera t ion o f the equ ipment as regards to i ts per fo rmance and
smooth and re l iab le work ing .
1.5 PRELIM IN ARY ACCEPTANCE
Aft er comp let ing the erect ion o f a uni t o r agreed port ion th ereof, th e successful Bidder shal l g ivea notice in wr i t ing stat ing that the job is complete in a l l respects and ready for prel iminary
acceptance. The job shall be visually inspected by representatives of the Successful Bidder and
Purchaser / Consul tant to ascerta in whether supply, fabr icat ion and erect ion are as per contract
drawings and Technical Specification. All observed defects, deficiencies and omissions shall be
noted down. I f the defects , de f ic ienc ies and omiss ions are not major in the op in ion o f the
Purchaser / Consul tant , th e successful Bidder shal l be issued a p rel iminary acceptance cert i f icate
m ention ing the d efects, def ic iencies and om issions. The no ted d efects, def iciencies and o m issions
shall be mad e good b y the successful Bidder w i th in a per iod o f 3 to 4 w eeks.
1.6 FINA L ACCEPTAN CE
Before com m encement of f inal acceptance test of t he bu i ld ing or un i t , the successful Bidder shal l
make avai lable required numbers of complete sets of ordinary pr ints of drawings, required
numbers of set of DOD l ist for the drawings and one set of reproducible f i lm of a l l drawings, a l l
representing As-Bui l t condi t ion ( i .e. a l l addi t ions and al terat ions done dur ing fabr icat ion and
erect ion shal l be incorpo rated in th e drawings).
The successful Bidder shal l attend to al l defects, def ic iencies and omissions noted down dur ing
prel im inary acceptance and aft er rect i fy ing or m aking good the abov e in a l l respects, shal l inform
10 days in advance the Purchaser / Consul tant for conducting f inal acceptance. Dur ing Final
Acceptance all defects, deficiencies and omissions noted earl ier shall be checked. The successful
Bidder shal l a lso make good any defect, def ic iency or omission not not i f ied dur ing ear l ier
prel im inary acceptance, but po inted out dur ing f inal acceptance. Final Acceptance cert i f icate shal l
be issued b y th e Purchaser after a l l defects, def ic iencies and om issions not ed und er pr el iminary
Technical Specificati on: Instructions To The Bidders Page 11 of 12
1.7 SCOPE OF W ORK
1.7 .1 The broad tu rnkey scope o f w ork sha l l be as per the fo l low ing:
Design, m anufacture , inspect ion , shop & pr imary coat o f pa in t & supp ly o f comple te p lan t &
equipm ent , fabr icat ion (shop & site) of bu i ld ing str uctur es & techno logical structu res, civ i l
construct ion mater ia ls , power d is t r ibu t ion , e lect r ics , ins t rumenta t ion & automat ion ,
i l lumination, a l l ut i l i t ies & services, in-plant road networks, drainage systems, landscaping,
f i re de tect ion & a larm system , f i re f igh t ing pum p house, as requ i red , fo r comple te & t roub le
free ope rat ion o f Coal Handl ing System in an int egrated m anner.
Basic engineer ing, detai l engineer ing and r eference category of d raw ings, operat ing softw are
and do cum ent s, in requ isi te cop ies, for approval o f NALCO/ RITES. Furt her , the Tenderer w i l lfur nish f inal basic & d etai l engineer ing draw ings, manufactu r ing drawings of fast w ear ing
i tems and non-standard i tems, as bui l t drawings, erect ion drawings/documents, operat ing
sof tware , opera t ion and m ain tenance manua ls in so f t ed i tab le fo rmat .
Receipt of mater ia l , loading / unloading, storage, civ i l construct ion, complete erect ion,
test ing, com m issioning, handing over of W agon Tippler Com plex to Purchaser, dem onstrat ion
of performance guarantee and post commissioning services for a per iod of six months after
commissioning. Preparat ion and approval of erect ion survey / a l ignment schemes, grouting
clearances, paint ing clearances, test ing of w elds, pressure test ing pro toco ls and oth er r e lated
site p rot ocols.
Deputat ion of representat ives of equipment suppl iers and technology suppl iers to si te for
supervision of er ect ion, test ing and com m issioning.
Applying f inal f in ish coat of paint as per approved procedure & shades before handing over,
f i rst f i l l of lubr icant & oi l , special too ls & tackles, mob i le equ ipm ent, handl ing & hoist ing
equ ipmen t e tc .
Supply of a l l commissioning spares. A l ist of such commissioning spares shal l be indicated
separately. Tender er shal l quote separately fo r t w o years spares and insurance spares along
w i th the ma in o f fe r .
Progress report ing as per agreed formats, provid ing documentary evidence of purchase
ord ers on sub vendors w i th add resses of con tact p ersons, attend ing al l s ite p rogress review /
engineer ing review m eetings at NALCO, Angul o r at RITES, Gurgaon / Bhubaneswar, ope ning
an equipp ed si te off ice w i th coord inator o verseeing al l act iv i t ies.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 2 of 66
2.1.5 Sizer
(a) No. requ ired : One (1)
(b) Guaranteed (rated) capacity: 1200 TPH
2.1.6 E.O.T Crane
(a) No. of uni t : One (1)
(b) Guaranteed (rated) capacity (M ain/ Aux.) : 25 T / 5 T
2.1.7 Du st Control System
The parameters for the dust control system speci f ied hereinafter are intended for Contractor ’s
guidance only. Contractor shal l provide adequately sized and effect ive dust control system, the
performance of which shal l be guaranteed by the Contractor as required in the Technical
speci f icat ions. The performance guarantee test procedure is to be submitted by the Contractor.How ever, the capaci ty of th e offered system shal l not be less than t hat specif ied below .
(a.) Area Dust Supp ression System at W agon Tippler
(1) Location : W agon Tipp ler Top
(2) Capaci ty of each nozzle : 2.0 lpm at 2.5 kg/ cm 2
(3) No zzle spacing. : 500 m m
All nozzles to o perate simu ltaneously in each w agon t ipp ler area.
(b) Dust Supp ression System for oth er areas
(1) Operat ion : W ater sprayed w ith fogging nozzle(2) Location of spray : Al l coal loading and discharge point on th e conveyor
(3) Capaci ty / Pressure : 2.0 lpm / 2.5 kg/cm 2 in let of spray head
2.1.8 Service W ate r System
Service water conn ections are to be provid ed in con veyor galler ies & tu nnels at 50 m eter int erval
and on e (1) no . on each f loor o f Transfer Point .
(a.) Flow at each valve : 5 cub . m / hr
(b.) M inim um discharge Pressure at tap po int : 2 kg/sq.cm
(c.) No of pum ps : 2 nos.(d) No. of valves operated : 6 no s. sim ultaneou sly
2.1.9 Ven tilat ion System
A M echanical Venti lat ion System
For U nderground Areas a M in imum of 15 supp ly a i r changes and m in im um 7 exhaust a i r
changes per hou r.
For o ther Areas a M in imum of 10 supp ly a i r changes per hour .
B. Pressur ized Venti lat ion System : M inim um 15 supply a ir changes per h our
C. Air Cond ition ing System :
Adequate numb er o f a ir changes to M ain ta in un i fo rm temp . & hum id i ty .
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 4 of 66
Guidel ine for w agon t ipp lers issued b y RDSO – G33 (Rev. 1) of M ay 2010 w ith lat est
amendm ents if any.
3.2.2 This Sub -sect ion shall be read in conjun ct ion w ith Electrical Sub -section s.
3.3 Construct ion and Design
3.3.1 Construct ion
Control desks/panels and annunciat ion system shal l be provided as per the requirement of
electr ical Section. Annunciat ion’s, indicat ions, e lectr ical meters and instrumentat ion shal l be
pro vided as speci f ied. Amm eters shal l be pro vided on cont rol desk for a l l mo tors rated 30 kW and
above and fo r a ll equ ipment .
3.3.2 DesignThe Cont ractor shall provide a com prehen sive cont rol indicat ion and annun ciat ion schem e for th e
p lant & equ ipment under wagon t ipp le r and conveyor system package and in tegra te the same
wi th the ex is t ing contro l & moni to r ing scheme o f the CHP. Contractor sha l l fu rn ish a b lock
d iagram and w r i te -up on the schem e proposed. The f ina l scheme w i l l be approved by the Ow ner
and the Contractor shal l be required to execute the approved scheme. In general , inter locking
shall be achieved t hrou gh feed-back signals from f ie ld equipm ent . A com prehen sive Annun ciat ion
and Indicat ion scheme shal l be provided such that, i t wi l l be possible for the operator to locate
and identi fy the faul t from the display ace of Control desk. The scheme shal l include the basic
remote contro l ins t rumenta t ion , ind ica t ion and annuncia t ion requ i rements as per var ious
techn ica l spec if icat ion requ i rements. However , t he Contractor may o f fe r any a l te rnat ive pr oposa lw hich he considers to b e equal , sup er ior t o t he schem e as descr ibed in subsequent clauses below
for ach iev ing re l iab le and t roub le f ree opera t ion o f the p lan t , fo r considera t ion o f th e Own er .
4.0 OPERATION AND CON TROL PHILOSOPHY
4.1 The Wagon T ipp ler contro l room shal l be loca ted by the side o f Wagon Tipp ler to accom mo date
contro l & mon i to r ing equ ipm ent o f wagon t ipp le rs . I t sha ll a lso have a bat te ry room .
4.2 The exist ing coal handl ing system is being contr ol led from th e fo l low ing cont rol poin ts. The
exist ing cont rol phi losophy of th e coal handl ing plant is being descr ibed below for the cont ractor
to understand the exist ing system and sui tably p lan integrat ion of the controls and inter locks ofthe proposed contro l system o f the wagon t ipp le r package w i th t he ex ist ing system .
4.2.1 Ow ner’s Exist ing Coal Han dling Plant Con trol Room
Operat ion o f t he CHP equ ipment is be ing contr o l led f ro m the Ow ner ’s CHP contr o l room .
(a.) Con veyo rs, feed ers, flap gates, hydraulic coup lings etc.
(b.) Com plete Du st Supp ression system & service wat er system .
(c.) Venti lat ion system (group/ individual contro l as required).
(d.) In l ine M agnetic separator s and Suspended M agnet (ON/ OFF contr ol w i th ind icat ion).
(e.) M etal Detecto rs (ON/ OFF contro l w i th ind icat ion ).
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 6 of 66
conveyors w i l l also stop sequent ia lly ( in the r everse sequence) a l lowing t im e delays for clear ing
the be l ts.
M anua l M ode : In M anua l M ode, the opera tor w i ll sta r t t he conveyor system , in t he samesequence as in Aut o m ode fro m con tro l desk. The operato r w i l l a lso stop th e conveyor system, by
press ing "System stop" o r ind iv idua l “S top” push but tons/command f rom contro l desk in the
reverse sequence. System Start and System Stop PB’s and locat ed on th e Own er ’s Cont rol Desk.
4.3.2 Con veyor System
(a ) Norm al ly t he op era t ion o f the apron feeder , sizer and the recla im conveyor sha l l be contro l led
f rom main contro l room for evacuat ing coa l f rom t ipp ler hopper .
(b ) The approach of a Rai lway wagon rake to the plant shal l be signaled (visual and audible) in the
w agon t ipp le r Cont ro l room as w e l l as to th e main coa l hand l ing p lan t cont ro l room , as soon as
the rake come w i th in 100 m eters d istances f rom the w agon t ipp ler .
(c ) Each conveyor shal l be protected against damage to the edge of the bel t due to excessive
s ideways movement by prov id ing adequate number o f be l t sway swi tches. In add i t ion , each
conveyor shal l be provided w ith o ne (1) No. speed d etect ion device (zero speed switch ). The zero
speed swit ches shal l be d esigned to sense be l t speed.
(d ) All the con veyors shal l be pro tected f rom rol l back due to p ow er fa i lure by pro vid ing mechanical /
or e lectr ical locking system .
(e ) The s tar t ing sequence o f the conveyors sha l l fo l low a d i rect ion opposi te to tha t o f f low o f
mater ia l . The detai ls of Coal f low diagram of the exist ing stage-I CHP shal l be furnished to the
successful bidder.
(f ) Any ind iv idua l equ ipment (be l t conveyor e tc . ) shou ld no t be a l lowed to s ta r t un less the
equ ipment immedia te ly fo l lowing the same in the d i rect ion o f f low o f mater ia l i s a l ready in
opera t ion .
(g ) Pul l -cord switches shal l be provided along the length of each bel t conveyor, which shal l enable
the respective conveyor to be stopped immediately. Each pul l operated chord switch and bel t
sway sw itch shal l be tagged and shal l be iden ti f iable in the m ain contro l room .
(h ) Siren shal l be pro vided to fo re-warn p ersonnel wo rking nearby wh en star t ing any conveyor.
(i ) Inter lo cking o f var ious conveyors shal l be achieved w ith Flap Gate, l imi t sw itches and zero speed
switches.
(j ) M ot ors shal l star t only wh en the brake/ rai l c lam p i f-provided, is in “o pen” cond i t ion. This signal
sha l l be obta ined f rom l im i t swi tch prov ided fo r t ha t pu rpose.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 7 of 66
(k ) Once a conveyor tr ips, f lap gate direct ing coal from this conveyor shal l change over i ts posi t ion
w i th a t ime de lay and sha ll come back to th e or ig ina l posi t ion aga in , to p revent jamm ing o f ga te .
(l ) Where ever scoop type coup l ing prov ided fo r HT motors , the coast ing t ime o f respect ive
conveyor, thruster brake, actuator select ion and the chute size shal l be so selected such that
th ere is no spi l lage of coal from any dow nstream conveyors.
4.3.3 Interlocking
a) The fo l low ing con veyors / eq uipm ent are con sidered und er inter lock scheme :-
(1.) All conveyor s
(2.) All gat es
(3.) W agon t ippler(4.) Apron Feeder
(5.) Doub le ro ll Sizer
b ) The fo l lowing equ ipm ent w i l l no t come under in te r lock o f th e conveyor scheme.
(1.) Al l dust supp ression system s & service wat er system .
(2.) Venti lat ion system s
c) All conveyors and equ ipm ent have local push butt on stat ion s each consist o f :
(1.) Pos - I, Pos - I I & sto p bu tt on for f lap gate
(2 .) Em ergency s top pu sh b ut t on (Red) fo r o ther equ ipment
d ) Belt scale is star ted wh en relevant con veyors are star t ed.
e) The dust suppre ssion system s w i ll be energized as soon as th e conveyor s are energized.f) Coal Handl ing plant shal l be tr ipp ed in case of d etect ion of f i re. Necessary input contact shal l
be made ava ilab le to t he Cont ractor in the Ow ner ’s main contro l roo m .
g) In te r lock fo r H.T. M oto r : H.T. m oto rs used w i ll cont inue to run on n o load by d isengag ing the
f lu id coupl ing in case of fa i lure of any process inter lock. The H.T. motors wi l l however be
tr ipped in case o f any m otor fau l t l ike O/ L, h igh m otor w ind ing tempera ture e tc . In add i t ion ,
in case o f norm al stop comm and, a f te r runn ing o f th e system , mo tors w i ll stop .
h ) The fo l lowing are the var ious safety inter locks for the conveyors and other equipment. This
l ist is indicat ive only and t he Contractor shal l develop a com prehensive inter locking schem e.
Conveyorsa). Pul l - Chord switch - no t op erated
b). Bel t sway switch - no t operat ed
c). Underspeed switch - c losed at 90% speed of the conveyor wi th in designed accelerat ing
t ime .
d ) . M o to r p ro tect i on - no t t r i pped
e). Local sto p PB – reset
f) . Chute Block sw itch - not op erated.
g). Brakes for conveyo r – not operat ed.
h). Tr ip ci rcui ts heal t hy.
i ). Tem p. of f lu id coup l ing oi l - not h igh
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 10 of 66
motor wi l l t r ip bu t the succeed ing conveyors / equ ipment wi l l cont inue to run . The s ta tus
ind icat ion aga inst the preced ing conveyors / equ ipment w i l l s ta r t s low b l ink ing w h i le t he fau l ty
conveyor / equipment wi l l be fast b l inking. Start command shal l not be in i t iated unless reset
but t on in p ressed a f t e r c learance o f fau l t .
The sequen ce of operat ion of th e ann unciat ion system shall be as follows:-
Condit ion Status
N orm a l : Ann . W indow : Of f .
Statu s indicat ion : Steady glow
Buzzer : Off.
Fault : Ann. W indow : B link ing.
Statu s indicat ion : Fast b l inking
Buzzer : Sou ndin g.
Press Accept PB.
Ann. W indow : Steady g low .
Statu s indicat ion : Fast b l inking
Buzzer : Off .
Press Reset PB (W hen fault is cleared):
Ann . W indow : Of f .
Statu s indicat ion : i ) Steady bl inking ( i f on selected path )
i i) Of f ( if n o t on se lected p ath)
Buzzer. : Off .
4.3. 7 Du st Suppre ssion System
(a. ) Conveyors / Equipm ent
1. I t shal l be possible to spray the water on to coal stream only when corresponding
conveyors/equ ipm ent ’s a re runn ing w i th m ater ia l at spray app l ica t ion po in ts .
2. I f a runnin g pump tr ip s stand-by pum p shal l star t auto m atically. It shal l be possible to select any
of t he pum ps as auto s tandby f rom main CHP contro l room .
3. Pump/pumps shal l tr ip wi th a t ime delay, i f d ischarge valves fa i l to open. Sui table pressure/f lowswitch shal l be pro vided to sense th is condi t ion .
4. Pum ps shal l tr ip in case of low level of w ater in t ank.
5. All feeding pum ps to t ank shal l tr ip in case of h igh-high level in tan k.
6. All the cont rols shal l be thro ugh cont rol desk.
(b . ) W agon unloading
1. System shal l be operat ed fro m local cont rol panel .
2. Dust supp ression system shall be provided t o cover t he W T Hopper.
3. Pum ps sha l l be star ted m anua lly o r f rom . If any o f the pum p/ pum ps t r ips, stand-by pump/ pum ps
shal l star t autom atical ly. I t shal l be possible to select any of t he pu mp s as aut o stand - by.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 12 of 66
5.0 W AGON TIPPLER
GENERAL
Rotaside / Rotary wagon t ippler shal l be furnished complete wi th a l l structural members, t ipplerplatform, t ipping mechanism, t ippler dr ive motors, brakes, coupl ings, shaft ing and al l automatic
contro ls fo r pos i t ion ing , t ipp ing and d ischarg ing the ent i re contents o f the wagons in to the
hopper .
5.1 W agon Unloading System
5.1.1 The rake comprising of speci f ied maximum 58 number of wagons shal l be pushed into the reach
of in -hau l equ ipment by a locomot ive . Fur ther p lac ing o f wagons over t ipp le r p la t fo rms and
carry ing away the empt y w agons sha l l be accompl ished w i th the he lp o f a s ide arm charger under
scope of b idder.
5.1.2 W agon unloading equipm ent shal l be sui table to handle any t ype of w agons being used by Indian
Rai lways for t ransportat ion of coal . Thu s side arm charger and w agon t ippler shal l be sui table to
handle al l standard broad gauge (1676 mm) wagons of RDSO design used by Indian Rai lways
confo rm ing to latest revision of IS: 10095.
5.1.3 M aximu m mo ving d im ensions o f locom ot ive & wagon as per Ind ian Ra i lw ay norm s sha l l be
adopted fo r p rov id ing c learances w i th respect to st ructures, equ ipm ent and t ipp le r a r rangem ent .
5.1.4 Complete wagon t ippler and accessor ies shal l have the approval of concerned Indian Rai lway
Author i t ies and RDSO. Further, the contractor shal l submit to the Owner detai led drawings of
wagon t ippler and accessor ies including civi l and structural drawing only after gett ing the same
approved f rom the concerned Ra i lw ay author i t ies.
5.1.5 The bidder shal l obtain al l statutory approvals from the relevant Rai lway author i t ies, before the
w agon t ipp ler com plex is pu t in to opera t ion . Any s ta tu tory paym ent charges, to b e made to the
concerned author i t ies shal l be to Bidder ’s account. I t is the responsibi l i ty of the Contractor to
carry ou t any m odi f ica t ions as requ i red by th e Ra i lway auth or i t ies, a t no ext ra cost to the Owner .
5.2 W agon Tippler Hoppe r
5.2.1 The w agon t ipp ler hopp er shal l be of RCC construct ion and adequat ely sized to accomm odat e th e
coal load for at least tw o (2) no s. 8 w heeled w agons of RDSO design u sed by Indian Rai lways. For
effect ive volumetr ic capaci ty computat ion of the hopper, the angle of repose of coal shal l be
consider ed as 37°. The m inimu m val ley angle of the ho pper shal l be con sidered a s 60°. The
hopper shal l have opening below which apron feeders shal l be provided to evacuate coal from
the hopper and feed onto associated bel t conveyors below. Complete inside surfaces of the
hopper sha l l be pro v ided w i th 50 mm th ick gun i t ing . Fur th er i t sha ll be possib le to emp ty out a l l
the coa l , w i thout any dead stock f rom the hopper .
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 13 of 66
5.2.2 Steel grat ings of m esh size 350 mm x 350 mm o ver wagon t ippler hopper shal l be provided. The
grat ings sha l l be bu i l t o f m in im um 200 mm x 36 m m th ick f la ts. The hop per and gra t ings sha l l be
designed fo r movement o f f ron t end loader /bu l ldozer over them. Bu l l -dozer we ight sha l l be
consider ed as abou t 35 T.
5.3 COD ES AN D STAND RDS
The design, manufacture, inspection and test ing of Wagon Tippler shal l comply wi th a l l the
current ly appl icable statu tes, regulat ions and safety codes in the local i ty wh ere the equipm ent is
to be instal led. The W agon Tippler shal l confo rm to t he latest edi t ion o f th e standa rds and codes.
Other international ly acceptable standards/codes, which ensure equal or h igher performance
than tho se specif ied, shall a lso b e accepted. N oth ing in th is speci f icat ion shall be construct ed t o
rel ieve the contractor of the required statutory responsibi l i ty. In case of any confl ict in the
standard and th is speci f icat ion , the decision so th e Engineer shal l be f inal and b inding.
5.4 DESIGN REQ UIREM ENT
Keeping in view Techn ical guid eline issued by RDSO ( Research & design services or ganizatio n )G
33 Rev.01 issued on May’10 & effect ive from Dec’10, the speci f icat ion of wagon t ippler a long
w i th apron feeder & sizer to be designed as under :
a) W agon t ipp ler capaci ty : 25 Tips per Hour
b ) Load handl ing capaci ty of w agon t ipp ler : 140 Ton
5.4.1 The wagon t ippler shal l be sui t able to un load a coal w agon by l i f t ing and rot at ing it s idew ays. Theangle of t ip shall be at least 160° giving 60° angle to t he side of t he w agon fo r em pt ying the coal
con ten ts in to the hoppe r be low.
5.4.2 Dur ing each cycle of operat ion , th e t ipp ler shall be capable of hold ing, com pletely unloading and
rep lac ing the wagon to i ts o r ig ina l pos i t ion wi thout damage to the t ipp le r o r the wagon or the
t rack.
5.4.3 The t ip pler shal l be sui table for cont inuous operat ion, 24 hours a day, roun d the clock.
5.4.4 The wagon t ippler stru cture shal l be designed to confo rm to th e requirem ent s of Indian Rai lway’s“ Research, Design and Standard s Organisat ion, (RDSO) - G 33 Rev.1 ” w i th regard t o t he nat ure o f
loading, im pact factor and al lowab le stresses. I t shal l be t he sole respon sibi l ity o f t he cont ractor
to ensure that each and every component of the wagon t ippler is adequate in r ig id i ty, strength
and of h eavy duty construct ion o f f i rst c lass qual i ty to guarantee against fa i lure or m ajor dam age,
assuming proper maintenance and usage. The t ippler shal l be designed to al low passage of a l l
standard broad gauge (1676 mm) Indian Rai lways diesel locomotives over t ippler table at
restr icted speed.
5.4.5 The wagon t ippler shal l be sui tably counte r balanced at each stage of operat ion so as to requ ire
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 14 of 66
5.5 W AGON TIPPLER W EIGHIN G SYSTEM
5.5.1 This speci f icat ion cal ls fo r an electron ic stat ic w eighing system t o measure / record t he quan tumof coa l , wagon wise on the wagon t ipp le r tab le be fore & a f te r t ipp l ing . The we ighbr idge wi th
adequate no. o f load ce lls sha l l be prov ided beneath th e wagon t ipp le r p la t fo rm w i th a m in imum
accuracy of 1% of the gross weight of the wagon. The platform shal l be freely supported on the
w eigh br idge befo re and after t ipping for accurat e w eighing. The w agon t ippler w eighbr idge shal l
be designed t o stat ical ly w eigh t he w agons in an un coupled condi t ion. The system shal l com prise
of a weighbr idge, a t ippler table, load cel ls, weight d ig i t izer and an inte l l igent terminal wi th
pr in ter w i th th e faci li ty fo r com put er ized pr in ted ou tput o f da ta gross w e ight , ta re w e ight , w agon
no., t ime, date etc. the weighbr idge shal l be chosen to accommodate al l types of wagons as per
RDSO guidel ines to move coal . The weighbr idge shal l be supported on minimum 4 nos.
compr ession type load ce l ls m ount ed on f ree mo t ion s t ructura l un i t assembly .
Al ternat ively, in-mo tion w eigh scales in bot h in-haul and out -hau l tracks shal l be provided fo r th e
pu rpose. The load cells shall be sui table for du sty environm ental condi t ions. The cal ibrat ion o f th e
weigh br idge shal l be the scope of the bidder. The bidder shal l co-ordinate with statutory
author i ty to ge t the necessary stamp ing & o t her requ i rement s.
6.0 CON STRUCTION REQU IREM ENT
6.1 Cradle
6.1.1 The cradle shal l consist of a pair of heavy w elded steel p late sect ions re inforced w ith st i f feners
and connect ed by side bearer beams pivotal ly attached, each sect ion being f i t ted w ith a m assive
tru nion shaft carr ied in bron ze bushed cast steel bear ings on each side, bol ted to steel pedestal
carr ied on concrete pedestals. Circumferentia l dr iv ing rack shal l be r ig id ly bol ted to the
peripheries of the sectors. The sectors shall be made of cast steel. Necessary features of safety
against com ing down o f wagon t ipp le r in the event o f fa i lu re o f one o f t he dr ive p in ions and / o r
gear racks shal l be pr ovided and the same shal l be clear ly indicated in t he bid .
6.2 Rail Table
6.2.1 The rai l table shal l be constru cted of ro l led steel jo int s w i th standard steel ra i ls (52 kg/m etre)
m ount ed on i t . The t ab le sha l l be p ivo ted f rom arm s extended f rom the sectors . The t ab le sha l l be
covered w i th chequered p la tes betw een the ra ils.
6.3 Feeders and Clamp s
6.3.1 The w agon shal l be clamp ed auto m atical ly by hydraul ic system and f i rm ly on the cradle dur ing
the t ipp ing wi thout any damage or undue pressure on any par t o f the wagon and no hand
adjustm ent o f any sort shal l be n ecessary. Sl id ing side stop p ads shal l be o f resi lient m ater ia l to
prevent damage to e i ther the w agon or t he stops.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 17 of 66
8.1.2 The rake com prising of speci f ied maxim um num ber of wa gons shal l be pushed into the reach of
inhau l equ ipm ent by a locomo t ive . Fur th er p lacing o f w agons over t ipp le r p la t fo rm and m oving
out the emp ty w agons sha l l be accompl ished w i th t he he lp o f s ide arm charger .
8.2 COD ES & STAND ARDS
The design, manufacture, inspection and test ing of Side Arm Charger shal l comply wi th a l l the
current ly appl icable statu tes, regulat ions and safety codes in th e locali ty w here th e equipm ent is
to be instal led and al l no rm s st ipu lated b y RDSO- G 33 Rev.1. The Side Arm Charger shal l conf orm
to the latest edi t ion of the standards and codes. Other international ly acceptable
standards/codes, which ensure equal or h igher performance than those speci f ied, shal l a lso be
accept ed. Nothin g in th is specif icat ion shal l be con str ued to re l ieve the con tracto r of th e required
statut ory responsibi l i ty. In case of any confl ict in t he standard and th is specif icat ion, th e decision
of th e Engineer shall be f inal and b inding.
8.3 DESIGN REQ UIREM ENT
8.3.1 A single m odu le of side arm charger shal l be used for inhaul and out haul op erat ion s. Thus, side
arm charger shal l be used for indexing forward the rake of 58 nos loaded wagons, p lacing
decoup led wagons on the t ipp le r tab le and ou t hau l ing the emp ty w agons.
8.3.2 The rake of 58 loaded wa gons w i l l be brou ght by locomo tive and placed on the ret ipping l ine
such t ha t t he lead ing wagon w i ll be w i th in t he reach o f th e side arm charger . Now the s ide arm
charger wi l l be coupled to the leading wagon, pul l the rake of 58 nos. loaded wagons towardst ipp ler table. The f i rst w agon w i l l be decoup led manual ly from th e rake and signal wi l l be given to
the s ide arm charger opera tor tha t the wagon is de-coup led. Now the lead ing wagon wi l l be
placed central ly onto the t ippler table by side arm charger, (simultaneously e ject ing the empty
w agon f r om the t ipp le r tab le) . A f te r t he loaded wagon is p laced on t he t ipp le r tab le , the arm is
de-coup led f rom the loaded w agon. Adequate c learance betw een t ipp le r tab le and emp ty w agon
shal l be ensured. The side arm charger wi l l stop at the end of i ts strokes, the arm wi l l be swung
vert ical ly-up and the machine wi l l move towards in-haul d irect ion and occupies the in i t ia l
pos it ion . In the m eant ime, the t ipp ler w i ll t ip t he loaded wagon p laced on the t ipp le r tab le and
re turn to i t s o r ig ina l pos it ion . Before t ipp l ing opera t ion o f wagon t ipp ler is com ple ted, the arm o f
the s ide arm charger wi l l be swung to hor izonta l pos i t ion and wi l l be coup led to the rake o fremain ing loaded w agons a t w a i t ing pos it ion ju st be fore th e t ipp le r tab le and is now ready fo r the
next cycle to star t. After the t ippl ing operat ion of wagon t ippler is completed the cycle wi l l be
repeated.
8.4 TECHN ICAL REQUI REM ENTS8.4.0 CON STRUCTION REQU IREM EN T
8.4.1 The Side Arm Charger shal l be sui table to hand le 58 num ber of loaded wagon s. The pu sher arm
shal l be vert ical ly rotatable arm mounted on a carr iage running back and for th paral le l to the
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 20 of 66
end shal l be of sturdy steel construct ion sui tably st i f fened. The sprocket shal l be made of cast
al loy steel wi th case hardened teeth or forged steel . The tract ion wheel shal l be made of cast
steel wi th case hardened surface. Tensioning arrangement w i th suff ic ient t ravel shal l be provided
for t he ten sioning of the chain . Com plete d r ibble bel t system consist ing of h ead pul ley, ta i l pul ley,dr ive, m ot or, str ingers, deck plates etc. shal l be pro vided.
10 .5 DA TA SHEET
Capacity (TPH) : 150 0 M TPH ( Design)
1200 M TPH ( Rated )
Angle of Instal lat ion : Hor izont al
Chain Link : Forged alloy Stee l
Apron pan : M S fabr icated w ith w ear resistant p late or special a l loy steel .
Tract ion w heel : Cast SteelRollers : Forged Alloy Steel
11.0 SIZER
GENERAL
A Sizer com plete w i th a l l accessor ies shal l be fu rnished in w agon t ipp ler com plex as speci f ied.
11.1 COD ES & STAND ARDS
The design, m anufactu re, inspection and t est ing of a Sizer un i t shal l com ply w i th a l l th e current ly
appl icable statutes, regulat ions and safety codes in the local i ty where the equipment is to be
instal led. The Sizer shal l conform to the latest edi t ion of the standards and codes. Other
international ly acceptable standards/codes, which ensure equal or h igher performance than
th ose speci f ied, shal l a lso b e accepted . Noth ing in t h is speci f icat ion shall be con stru cted t o r e l ieve
the contractor o f t he r equ i red s tatu t ory responsib i l ity . In case o f any conf l i c t in t he s tandard and
th is specif icat ion, t he d ecision of the Engineer shal l be f inal and bind ing.
DESIGN REQU IRM ENTS
The faci l i ty shal l be provided w ith a tw in shaft coal low h ead room sizer uni t . The sizer uni t shal l
be capab le o f hand l ing up to 300mm size m ater ia l f rom the apron feeder d ischarge chute .
The rated capaci ty o f s izer shal l be 1200 TPH m inimum . The sizer shal l redu ce over size m ater ia l
w i thout caus ing undue degradat ion o f qua l i ty f rom ( - )300 m m to ( -) 100 mm product ion size . The
equ ipment sha l l be su i tab le fo r cont inuou s opera t ion and shal l be ab le to hand le w et m ater ia l.
The shaft Sizer shal l have tw o cont ra-rotat ing shafts having attached w ith t he appr opr iate sizing
teeth with scrol l arrangement. The sizer shal l be of extremely robust construct ion and of
adequate s t rength to wi thstand heavy duty opera t ion wi th genera t ion o f min imum f ines and
oversize. The teeth of the Sizer shal l be able to continuously agi tate scrol l in feed mater ia l to
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 22 of 66
belt conveyor systems, wagon t ippler , s ide arm charger, apron feeders, var ious pumps of dust
suppression system , fans for venti lat ion system , mon orai l e lectr ical hoists and o th er equipm ent’s
specif ied in th is speci f icat ions. Var ious requirem ent s as spel t out in t he Technical Speci f icat ion s
for individual equipment’s shal l be taken into considerat ion whi le designing the associated dr ivecha in equ ipment ’s.
12.1 COD ES AND STAND ARDS
The design, manufacture, inspection and test ing of Dr ive Equipment shal l comply wi th a l l the
current ly appl icable stat ut es, regulat ions and safety codes in t he local i ty w here t he equipm ent in
to be insta l led . The Dr ive Equ ipment ’s sha l l conform to the la test ed i t ion o f the fo l lowing
standards and codes. Other international ly acceptable standards/codes, which ensure equal or
higher performance than those, speci f ied, shal l a lso be accepted. Nothing in th is speci f icat ion
shall be constr ued to r e l ieve th e con tracto r of th e required statut ory responsibi li ty. In case of anyconfl ict in the standard and th is speci f icat ion, the decision of the Owner shal l be f inal and
binding.
IS:3688 : Dim ensions for shaft ends
IS:3681: General p lan f or spur & hel ical gears
IS:7403 : Code o f pract ice for select ion o f standard wo rm and h el ical gear boxes
12.2 DESIGN AND CONSTRUCTION REQU IREM ENTS
12 .2.1 GEAR BOXES
12.2.2 Gear Boxes shal l be of sealed type and m oun ted on m achined or ground surfaces.
12.2.3 The gearboxes shal l be designed for 24 ho urs cont inuous dut y and gear boxes shal l have
appropr ia te th ermal ra t ing .
12.2.4 The gears used shal l be hel ical con form ing to IS:3681 (latest revision ) or w orm r eduction u ni ts or
spira l bevel speed reduct ion uni t s conf orm ing to sui table Indian Standa rds. The dimen sion s of t he
shaft end shal l conform to IS:3688 or i ts latest revision . Above 40 kW dr ive rat ing, a l l gearboxes
shall be he l ical or be vel hel ical typ e only.
12.2.5 Recom m ended oi l grade shal l be comp atib le w i th gear int ernals l ike m ater ia l of bear ing, cages.Furt her, a l l gearboxes shal l have sui table b reather p lugs, d ipst ick, drain p lug etc.
12.3 COUPLINGS
12.3.1 Flexible / Rigid Cou plings
Approved type o f coup l ings sha l l be used fo r power t ransmiss ion depend ing upon duty
requirements. The design of the coupl ing shal l be such that i t can take shock and misal ignment
w itho ut sacr i f ic ing i ts eff ic iency. Geared t ype f lexib le coupl ing shal l be used on low speed side for
al l conveyors and other dr ive chains where gear box is provided. Other coupl ings in the dr ive
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 23 of 66
chains shal l be ei ther r ig id or f lexib le typ e, depend ing upon th e requirem ent of equ ipm ent design
and shal l be f inal ized du r ing detai led engineer ing.
12.3.2 Fluid Couplings
Fluid coupl ings shal l be prov ided in a l l the d r ive machinery fo r w agon t ipplers & associated b el t
conveyor system s if the actua l pow er requ i rem ent a t m oto r ou tp ut shaf t i s m ore than 40 kW . The
flu id coupl ing for LT motors shal l be of tract ion type. Cool ing water coi ls for tract ion type f lu id
coupl ing shal l not be accepted. Scoop tube type f lu id coupl ing shal l be provided for conveyors
with HT motors. Sui table electr ical ly operated actuators shal l be provided for scoop tube
operat ion from local as wel l as remote. Sui table provision for a l ternate manual operat ion shal l
a lso be kept. Separate pump with motor shal l necessar i ly be provided for ci rculat ing the f lu id
coupl ing oi l through oi l cooler . Independent arrangement for forced cool ing water supply using
2X100% capaci ty pumps to oi l cooler shal l be provided by Contractor. Sui table inter lock usingf low swi tches sha l l be prov ided in bo th o i l as we l l as water l ines to t r ip th e dr ive mot or in th e
event of f low in e i th er l ines fal l ing below / accept able levels. Sui tab le pressure indicators and f low
indicator s shal l be pro vided in t he cool ing w ater l ines along w ith a l l- re levant valves, str a iners and
accessor ies. Necessary isolat ion valves shal l be pro vided in t he o i l / w ater l ine for ma intenance of
any equipm ent in t he l ine. Necessary inter lock shal l a lso be pro vided so th at t he HT mo to r cannot
be s tar ted f rom remo te / loca l un less pos it ion o f scoop t ube perm i ts no load s tar t o f th e mo tor .
Tr ipp ing o f downstream equ ipment wh i le the system is under normal opera t ion sha l l resu l t in
scoop tube re-posi t ion ing to perm i t no load run o f the concerned HT mo tor . Temp era ture sw i tch
shal l be provided in the oi l c i rcui t and shal l tr ip the system in case of h igh oi l temperature.
Select ion of rat ing & speed of actuator for scoop type f lu id coupl ing shal l be made taking intocons idera t ion the coast ing t ime o f downstream and upstream conveyors and the
engagement/d isengagement t ime achievable. The scoop tube operat ion must be such so to
ensure qu ick dra in ing out o f o i l f rom the opera t ing c i rcu i t , by prov id ing a doub le speed m oto r .
12.4 DATA SHEET: DRIVE EQU IPM ENTGENERAL
12.4.1 Cont inuou s M oto r Rating (Nam e Plate Rating) at 50 Degree Centigrade Amb ient tem p. for
Elect r ic M otors
a)
For conveyor s of bel t con veyor system s and bel t fo r In l ine m agnet ic separator : *1 20% ofactua l power a t d r ive m oto r ou tput shaf t a t speci f ied des ign capaci ty
b ) W T, SAC, apron feeders: * 110% of actua l pow er requ i rement a t d r ive mot or ou t put shaf t
at guaranteed (rated) capaci ty.
c) M on o-rai l hoists (travel and ho ist ing), var ious pum ps of DS system s, service wat er
systems, cool ing water system, potable water system and sump pumps: *110% of actual
pow er requ i rement a t d r ive moto r ou tpu t shaf t a t guaranteed ( ra ted) capacity .
d ) Vent i la t ion Fans: *110% of actua l power requ i rement a t d r ive motor ou tput shaf t a t
guaranteed (rated) capaci ty. In case of b el t d r ive, th e eff ic iency of t ransm ission shal l be
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 25 of 66
to be instal led. The EOT crane shal l conform to the latest edi t ion of the standards and codes.
Other international ly acceptable standards/codes, which insure equal or h igher performance
than those speci f ied, shal l a lso be accepted. Nothing in th is speci f icat ion shal l be construed to
rel ieve the contractor of the required statutory responsibi l i ty. In case of any confl ict in thestandard and th is speci f icat ion , the d ecision o f t he Engineer shal l be f inal and binding.
13.2 DESIGN REQU IREM ENTS AN D CON STRUCTION REQU IREM ENTS
The crane shal l be general ly of box type double girder construct ion and shal l designed for
appropr iate class of duty in accordance with BSS: 466/1960 and or IS:3177 to meet the
insta l la t ion and main tenance o f wagon t ipp le r and th e assoc iated equ ipm ent .
The br idge shou ld comp r ise o f tw o main g i rders w i th tw o o ut r iggers and th e end car r iage bu i lt
up from mi ld steel channel wi th adequate diaphragms or st i f f ing plates. Each br idge girder shal lbe fabr ica ted and d ispatched w i thout any sp l iced jo in ts .
Box Girder & End carr iage jo int s shal l preferably have f i t b ol ts. For a l l bol ted jo int s the ho les are
to be dr i l led and ream ed and bo l ts are to b e fo rce f it t ed .
Hand ra i ling sha l l be f i t ted o n bot h sides o f t he end car r iages and t h roughout the length o f t he
platfo rm (height of 1.1m ) paralle l to g irder. Size of th e hand rai l shal l be not less th an 25 m m b ore
heavy gauge steel p ipe. The vert ical p ipes shal l have f langes at the bottom for proper support.
Sui tab le hand rai ling should be p rovided on Cross Travel Trol ley also.
Al l Rot at ing parts & Overhang parts shal l be provided w ith sui table guard.
The end carr iages shal l be of approved design, wi th L type Brackets of substantia l construct ion
and am ple st i f fness bui l t u p of m i ld steel sect io ns securely welded.
The end car r iages o f the crane are to be mounted on doub le f langed whee ls o f approved
diam eter in accordance w ith IS: 3177. Numb er of w heels on each side o f the crane shall be 2 Nos
(Total 4 Nos in the Crane for Long Travel motion) The Wheel shal l be of forged steel having
composi t ion as Cr 55 Mn 75 (EN 9) hardened to 300-350 BHN wi th min imum depth 10mm
confi rming SAE 1055 / IS 1570 & shal l be f i t ted with ro l ler bear ings with dust proof seals. For
lubr icat ion , Grease nipples shal l be pro vided at convenient point s.
Twin d r ive system to b e adopt ed for Long Travel of E. O. T. in th e bay.
One w hee l in each car r iage is to be dr iven by fo rged s tee l gears th rough a mo tor mou nted on or
adjacent t o t he carr iage.
Long travel mechanism shal l be provided with, a thruster brake on each individual dr ive of the
track wheels. These brakes shal l be such that i t can be operated from both the control desk as
wel l as remote control . The brakes shal l be of post type with h inged shoes, l ined with good
qua l ity re in forced bond ed brake l in ing and su itab le fo r easy o f ad justm ent o f t he w ear on l in ing.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 29 of 66
14.2.15 All hoists/ chain pul ley blocks shal l be selected to have m inimu m h eadroom and shal l be selected
to l if t heav iest p iece o f equ ipment . Fur th er , it sha l l be possib le to hand le any equ ipmen t w i thout
d istu rb ing o ther equ ipment .
14.2.16 The hand chain wheels shal l be of cast steel , the wheels shal l be with f langes and designed to
ensure effect ive operat ion of hand chain. Further, sui table local brake shal l be provided as per
IS:3832 t o arre st and sustain loads in a l l w ork ing posi t ions.
14.2.17 The veloci ty rates, effor t on chain required to ra ise the safe working load and travel and speed
shall be w ith in th e l imi t speci f ied in IS:3832. Proo f load t est shal l be carr ied ou t as per IS:3832.
Balance requ iremen ts shal l be as discussed in ear l ier clauses perta in ing t o e lectr ic hoists.
14.2.18 Hoist for Gravi ty Take up arrangem ent and b end pul ley.
For handl ing bend pul ley, take-up pul ley and counter weights fo l lowing hoist ing arrangement
shall be prov ided:
(1 ) For handl ing bend pul leys, hooks of adequate capaci ty shal l be provided at the top of gal lery.
Further minimum four (4) nos. manual ly operated chain pul ley blocks of adequate capaci ty shal l
a lso be pro vided for t he ent i re coal handl ing plant f or hand l ing bend pu l leys.
(2 ) For handl ing take-up pul leys, manual hoist a long with mono rai l beam of adequate capaci ty
having cross travel , arrangement shal l be provided at bottom of gal lery to handle take-up pul ley
on ly of conveyors.
(3 ) For handl ing take-up weight, a separate manual hoist wi th mono rai l beam of adequate capaci ty
shal l be provided to hold complete counter weight ( inclusive of a l l counter weight b locks). This
ho ist sha ll be pr ov ided fo r ho ld ing th e counter w e ight and sha ll be located in the zone o f counter
w e ight t rave l.
14.3 CON STRUCTION REQU IREM ENT
14.3.1 The ho ist m echanism shal l consist of a grooved rop e drum dr iven by electr ic mo tor t hrou gh gears.
Each end of the rope shal l be anchored to the drum in such a way as the anchorage is readi ly
avai lable for maintenance. Each rope shal l have not more than two (2) fu l l turns of the drum
when the hook is at i ts lowest posi t ion and one (1) spare groove when the hook is at i ts h ighestpo si t ion . The leading rope taken b y th e drum shou ld not slope sidew ays wh en slack and i t shou ld
not b e caught be tw een the gear whee l .
14.3.2 Rope drum , gear box, b lock etc. shou ld be fabr icated ou t of w eldable qual i ty steel .
14.3.3 Trol ley wheels shall be of single f lange typ e in the taper tr eads. The wh eels shal l be moun ted on
anti fr ict ion bear ings and shal l be easily remo vable for repair / replacement .
14.3.4 The load hook shal l be swivel ing typ e forged circular shank sect ion and shal l confi rm to IS:8610.
14.3.5 All gears and bear ings shall be lubr icated by grease. All lu br icating poin ts shall be group ed
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 30 of 66
14.3.6 The bo tto m b lock shal l be of enclosed typ e and shal l have guard against rope jamm ing in norm al
use. It shal l have standard f orged swivel shank h ook f i t t ed on anti fr ict io n t hru st b ear ing. Lock to
prevent hook f rom ro ta t ion and lock ing ar rangement to prevent acc identa l un lock ing sha l l beprov ided. Pu l ley o f t he bot tom b lock sha l l be prov ided w i th an t i f r ic t ion b ear ings.
14.3.7 Al l parts requir ing replacement/ inspection/ lubr icat ion shal l be accessible wi thout need for
d ismant l ing o f o ther par ts /s t ructures.
14.3.8 Al l com pon ent s of hoists of identical capaci ty and duty shal l be interchangeable.
14.3.9 Hoists shal l have permanen t inscr ipt ion in Engl ish on each side readi ly recognizable from f loor
level stat ing safe w orking load.
14.3 .10 Pendant sha ll be p rov ided w i th f lourscent up / dow n/ fo rw ard / reverse t ravel push but t ons and
indicat ing lamps. I ts pow er supply shal l be l imi t ed t o 24V AC.
14.3.11 The cont rol panel shal l be wal l mo unt ed type & easi ly appro achable from th e f loor by a stand ing
m a n .
14.3 .12 For Inspect ion / m a in tenance o f ho ist com ponents a f ixed p la t fo rm (o f m in 1 .5 x 1 .5m) w i th
ladder shal l be pro vided fo r each hoist.
14.3.13 Each in l ine m agnetic separato r shal l have independent mo tor ised ho ist for i ts handl ing /
maintenance purpose. Each suspended magnet shal l a lso be provided with a dedicated electr ic
hoist.
14.4 DATA SHEET : M ON ORAILS AND H OISTS
1.0 GENERAL
1.1 Fun ctional Requirem ent : To transfer equipm ent’s to m aintenance area or ou tside th e
bui ld ing.
2.0 DESIGN & CON STRUCTION REQU IREM ENT
2.1.0 Hoists
2.1.1 Dr ive
( i) M ore than 2 .0 tonn e or mo re than 10.0 m li f t o r ho ists com ing out-s ide the
bu i ld ings: M oto r d r iven fo r bo th t rave l & l if t .
( i i) Oth er hoists including th e ho ists for handl ing takeup pul ley and takeup w eight :
M anua l fo r bo th t r ave l & l i f t .
2 .1 .2 M aximu m t ro l ley t rave l speed fo r e lect r ic ho ists : 15m/ m in
2.1 .3 M axim um Hoist ing speed fo r e lect r ic ho ists : 6 m /m in
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 32 of 66
15.2 DESIGN AND CONSTRUCTION
15.2.1 Chut es, Hoppers
15.2.2 The m inimu m val ley angle of chute s shal l be 60 degrees fro m ho r izont al .
15.2.3 Transfer chut es shal l be adequately sized and sloped to ensure sm oot h f low o f coal w i tho ut any
accum ula t ion anywh ere .
15.2 .4 Com ple te chute w ork above the dr ive f loor fo r conveyors prov ided w i th ‘ In - line be l t magnet ic
separators’ shal l be of 10 m m th ick SS - 304 in th e zone of m agnetic f ie ld.
15.2.5 Direct impact of m ater ia l on conveyo r bel t shal l be avoided by provid ing an incl ined surface at 60
degrees va l ley ang le a t the feed ing po in t to gu ide the mater ia l in the d i rect ion o f be l t t rave l .
Fur ther , chute construct ion be low f lap gate shaf t sha l l be such tha t there wi l l no t be anyaccum ula t ion o f coa l dust be tw een chute and f lap gate in th a t zone.
15.2.6 Hopp ers and Chut es shal l be m ade of m inimum 20 mm thick TISCRAL or equ ivalent m ater ia l .
How ever , Contractor to subm i t t est cer t i f ica tes sta t ing com posit ion o f m ater ia l and m echan ica l
propert ies of these wear resistant steel to the Owner dur ing detai l engineer ing. Long chutes
guiding f low from considerable height shal l be provided with impact p lates wherever change in
direct ion of f low takes place. Hinged inspection doors (generously sized) of leak proof
construct ion shal l be provided for access/ maintenance purpose, at approachable heights for
chut es and f lap gates. Al l chut es shou ld have one inspection doo r at every f loor and f or th e ones
in be t w een the f loors (more th en 1 .5 m eter above the opera t ing f loor leve l) su i tab le access fo rt ro ub le f ree m ain tenance sha l l be prov ided. M aximu m d istance between tw o inspect ion doors in
a chute shal l be 2 mtrs. For seal ing of inspection doors labyr inth type arrangement (wi th rubber
inserted in grooves) to be provided. In addi t ion to posi t ive locking arrangement, mounting bol ts,
to t igh ten th e door fu r th er aga inst rubber sha ll a lso b e prov ided.
15.2 .7 Bot tom side o f the chutes on w h ich t he coa l sl ides sha l l be w e lded to the s ide p la tes to fo rm a
trough. Bottom sides along with i ts adjacent sides shal l be f langed and made from TISCRAL or
equivalent mater ia l of 20 mm thickness. The non-str ik ing surface i .e. the covers of the trough
shal l be o f 10 m m th ick mi ld s tee l and bo l ted to the f lange prov ided on t he t rou gh. Ins ide w e ld ing
shal l be prov ided in the corners fo r perm anent seal ing. Fur t her , the chut e boxes not m ore th an1.5 m in length shal l be jo ined th rough bol t ed f lange connection t o for m the chut e legs. Adequat e
care shal l be taken to locate the f lange jo int away from f loor level for easy maintenance. Bol ted
f lange jo ints shal l be of d ust t ight construct ion and necessary seal ing mat er ia l shal l be provid ed in
al l the f lange connections for adequate seal ing. Complete chute work in the region of f lap gates
shall be fabr icated f rom 20 t hk TISCRAL or equivalent. In case of vert ical chute (val ley angle m ore
than 80 degree) complete chute, work shal l be of 20 mm thick TISCRAL or equivalent mater ia l .
Whi le f inal is ing the chute work inside the bui ld ing, arrangement for shi f t ing and replacing chute
legs, proper handl ing arrangement/wal l openings, tro l leys, hoists shal l a lso be provided. Whi le
fabr icat ing the chut e, the consti tuen t p late s used shal l be in one piece. No w elds in betw een shal l
be al low ed. In th e zones of d irect im pact due to Coal tra jectory , w ear resistant backing plate w i th
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 33 of 66
st i f fners shal l be provided in coal f low chutes. Simi lar backing plates & st i f fening arrangement
shall a lso b e provid ed on th e chut e surfaces having direct coal fa l l .
15.2.8 Hood s over the conveyor head pu l leys shal l be mad e of sui tably st i f f ened m inimu m 4 m m M .S.Plates and shal l be provided with h inged and gasketed inspection doors wi th sui table access to
them. Further, serrated rubber seal shal l a lso be provided at the very in let of head chute to
m inim ise dust nuisance.
15.2.9 Separate m aintenance sealed door shal l be pro vided for access to b el t c leaner s in head pul ley
hood impact p lates, f lap gates for maintenance and inspection doors shal l be of h inged with
po si t ive locking f acil i ty.
15.3. Skirt Boards
15.3.1 Skir t b oard shal l ensure cent ral ised loading of conveyor bel t t o avoid coal spi llage. Sui table ‘Skir t
Plates’ of minimum 3.0 meters length shal l be provided at each feeding point of conveyor. The
wid th o f the Sk i r t Boards sha l l be two- th i rd the conveyor be l t w id th . In the be l ts be fore S izer
House where coal of appreciable lump size (250 mm) is being conveyed, the gap between the
bot t om o f t he sk ir t b oard and the be l t sha l l be m ade to increase un i fo rm ly in t he d i rect ion o f be l t
travel . The height of the skir t boards shal l be suff ic ient to contain the mater ia l volume as i t is
loaded on th e bel t and shal l not be less than 750 m m . The skir t p lates shal l be f i t ted w ith m odu lar
segmented and replaceable rubber skir t ing pads having faci l i ty of adjust ing the pressure on the
bel t conveyor and shal l have provision of on l ine removal for the purpose of easy maintenance.
Such segm ented rubb er pads wi th i ts ho ld ing dow n ad justm ent a r rangem ents sha l l be o f p rovendesign. The edges of segm ented pads shal l be in stal led at an angle for provid ing a b ett er seal. Al l
care sha l l be taken w h i le des ign ing , to combine good sea ling wi th m in imum be l t w ear .
15.4 Flap Gates
15.4.1 The mo to r operat ed 2 posit ion f lap gates shal l be pro vided in tran sfer chut es as speci f ied and
shall be com plete w i th e lectr ical ly op erated actuato rs. The gates shal l be of rob ust construct ion
and su i tab le fo r t roub le f ree opera t ion . The face o f the f lap gate sha l l be made out o f 20 mm
t hick TISCRAL or equ ivalent m ate rial.
15.4.2 The equ ipm ent shal l be capable of being operated fo r at least 15 sw itchings per hou r at rated
load and t hrust and shal l be sui tab le for 10 No s. consecutive switch ings at rated load and th rust.
The equ ipm ent shal l be shop t ested to p rove th is requ i rem ent .
15 .4 .3 The m oto r ra t ing fo r the actuato r sha l l be so se lected as to p rov ide su f f ic ien t t h rust fo r op era t ion
of t he f lop gat es against th e m oving w eight of coal and/ or f lap gate. The f lap gate tr avel shal l be
in th e range o f 60 deg. to 70 deg. The mot or sha ll be comp le te ly dust t igh t .
15 .4 .4 Lever arm sha l l be prov ided betw een actuator and f lap gate shaf t fo r o b ta in ing requ i red th rust .
The l inkage m echanism prop osed shal l be indicated in th e Bid.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 34 of 66
15.4.5 The actuato rs shal l be capable of prevent ing any over travel . Sui table t ravel dependent l imi t
switch es contr ol l ing the t ravel of th e f lop gates on ei ther d irect ion shal l be furn ished. These shal l
be placed internal to t he dr ive uni t and shall be comp letely dust-proof . The l im it switch es shal l becapab le o f ad justm ents to vary the t o ta l length o f t rave l o f th e gates.
15.4 .6 Su i tab le th rust dependent l im i t sw i tches sha l l be prov ided in the actuator , wh ich sha ll t r ip o f f th e
actuator motor in case of excessive thrust due to jamming of the gates dur ing i ts travel in e i ther
direct ion . The same shal l a lso be int egral to th e dr ive uni t and shall be dust pro of.
15.4.7 Prov ision for a l ternat ive manual operat ion shal l also be mad e using declutchable handw heel. The
diameter of handwheel shal l be selected consider ing convenient force to be appl ied by a single
opera tor . How ever , m in imum d iameter o f hand w hee l sha l l be 500 m m . Limi t swi tch fo r sa fe ty o f
person o pera t ing the hand w hee l sha l l be prov ided.
15.4 .8 A l l the t w o w ay chut es, one way o f wh ich is lead ing tow ards the fu tu re conveyor , sha l l be
prov ided w i th b l ind f lange and f lap gate w i th a prov ision to m ount an actuato r in fu tu re .
15.4.9 The Cont ractor shal l furn ish calculat ions for select ion of actu ator for each location fo r appr oval of
Owner .
15 .4 .10 Su i tab le st i f fen ing ar rangement sha l l be prov ided betw een the tw o faces o f the gate p la te . At t he
end o f the travel the to ta l length of edge of t he f lap gate shal l rest on a sui table pro jected surface
from chute t o prevent leakage o f coa l dust th rough the ava i lab le c learance betw een chute and
flap gate.
15.4 .11 M aximu m feasib le counterw e ights sha ll be p rov ided fo r b e t te r u t i l isa t ion o f system . How ever , fo r
ca lcu la t ion o f th rust requ i red , the benef i t o f counterwe ight sha l l no t be taken in to
considerat ions.
15.4.12 Sui table sel f a l igned double row bal l bear ings in dust t ight housing shal l carry the gate shaft.
Sui tab le pro vision f or re-greasing shal l be p rovided.
15.4.13 For standard isat ion p urp oses, only one standard t ype of actu ato r for f lap gates shall be provid ed.
The standard type actuator shal l be selected for maximum thrust as calculated for var ious
locations. Flap gate actuator as a whole and individual component wise shal l be completely
inter changeable for a l l locations.
15.4.14 The m ater ia l of shaft shal l be EN-8 or equ ivalent . The diam eter o f th e shaft shall be sui table for
m oto r sta l led condi t ion and associated tw ist ing.
15.4 .15 Approach/ main tenance p lat fo rms comp le te wi th the chequered p la te f loor , hand ra i ls , ladders
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 37 of 66
16.2 Scope
16.2.1 Plain W ater Dust Sup pr ession System
Comple te wi th water supp ly system, p ip ing , spray heads, pumps, d r ive motors wi th canopy(wherever required), coupl ings with enclosure, e lectr icals, support ing structures,
approach/maintenance platforms, handl ing for equipment, c iv i l and structural works and
necessary accessor ies shal l be pr ovided f or W T hopp er to p & al l t ransfer point s, etc.
16.2 .2 Sum p Pump
4x100% sum p pu mp s a longw i th leve l sw i tches and p ip ing up to n earest Own er 's d ra in (max. up to
50.0 meters from outside the bui ld ing) shal l be provided at a l l locations wherever natural
drainage is not possib le. Sump pumps along with drain pi ts shal l be provided at other locations
also, i f r equired, du r ing detai led engineer ing stage. Sealing pum ps w ith valves, p ip ing f i t t ings andot her accessor ies for sealing of sum p p um ps shal l be pro vided.
16.2.3 Service W ate r System
Service water d istr ibut ion system complete wi th water supply system, valves, quick coupl ings,
hose pipes with nozzle, p ip ing, pumps, dr ive motors wi th canopy, coupl ings with enclosure,
electr icals, including support ing structures, handl ing for equipment’s, c iv i l and structural works
and necessary accessor ies shal l be provided throughout the coal handl ing plant area in
Cont ractor ’s scope.
16 .2.4 Pipings, Fitt ings, V alves an d Specialities
The m ater ia l to be supp l ied fo r comp le t ing the p ipe wo rk sha l l inc lude but no t be l imi ted t o t he
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 39 of 66
16.5 .2 W ater sha l l be drawn f r om the w ater sto rage tank by 2x100% e lect r ic m otor d r iven pum ps and
discharged into tank from where 2x100% duty electr ic motor dr iven pumps shal l d ischarge the
water via a pipe network system through spray heads at the dust suppression zones. Solenoid
valves shal l be pro vided fo r open/ close contr ol of w ater l ine to each spray head. Each spray headshall consist of m inimu m 4 no s. nozzles. Spray heads shall be pro vided at coal loading and receipt
zone. Pressure at in let t o spray h ead shal l not be less than 2 .5 Kg/sq.cm(g).
16.5.3 The dust supp ression system o ver the W T hopp er shal l have a canopy on w hich fogging no zzles
are f ixed at speci f ied distance. Each nozzle header shal l be provided with adequate number of
spray nozzles spaced a t 500 m m in terva l so tha t t he ent i re length & w id th o f the w agon t ipp le r
hopp er are covered by a gr id of no zzles. Furt her, th e wat er spray shal l be of fogging type w ith a
minimum pressure of 2.5 kg/sq.cm(g) at spray nozzle in let. I t should be possible to operate any
number of zones simultaneously. The operat ion of wagon t ippler dust suppression system shal l
be automatic so that the fogging water spray shal l get act ivated only when the t ippl ing is inopera t ion .
16.5.4 Each spray head shal l have a provision for instal l ing a pressure gauge when ever required. Furt her,
pressure gauges shal l be pro vided at least at t w o location s.
16.5 .5 Sum p Pumps
Sum p pu mp s shal l be vert ical centr i fu gal typ e w ith separate d ischarge pipe and shall be capable
of developing required head at rated capaci ty for continuous operat ion. Sump pumps shal l be
sui table for hand l ing coal slurry & sludge. Head capacity cu rve of t he pu m p shal l be r ising type upto the shut o f f cond i t ion . Sum p pum ps a longwi th leve l sw i tches & p ip ing upt o nearest Ow ner 's
drain (max upto 50.0 mtrs. from outside the bui ld ing) shal l be provided at a l l locations wherever
natural drainage is not possib le. Further sump pumps alongwith drain pi ts shal l be provided at
other locations also, i f required, dur ing detai led engineer ing stage. The capaci ty of each pump
shall not b e less th an 50 cub. M / hr. Cont inuous mo tor r at ing (name plate rat in g) at 50 deg. C. for
sump pu mp sha l l have a t least 10% marg in above the m axim um load demand o f the equ ipm ent in
the ent i re opera t ing range ( inc lud ing run out cond i t ion o f pum ps in case o f para lle l opera t ion) .
The maxim um load dem and shal l include th e dr ive losses in the t ransmission system . Size of th e
sump p i t sha ll no t be less than 2 .0 m eters x 2 .0 m eters x 2 .5 m eters. One no. o f se t t l ing p i t , o f
adequate size, before the sump pi t shal l a lso be provided so that water wi thout heavy coalpart ic les goes into sump pump pi t . High and low level switches shal l be provided in the sump
p u m p p i t .
16.5.6 Service W ate r (SW ) System
Service water connections are to be provided in conveyor gal ler ies and tunnels at 50 meter
intervals. Adequate number of these connections shal l be provided in a l l t ransfer houses with
minimum one no. at each f loor. Each connection shal l be provided with one (1) no. 32 NB globe
valve and quick coupl ing. One (1) No. Hose pipe with nozzle shal l be provided in each bui ld ing.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 43 of 66
hangers and components for a l l p ip ing shal l be selected and approval obtained from the
Owner .
(f ) All p ip ing shal l be rou ted on ground on concrete p edestals and at road crossings, th ese shal l
be la id t h rough hum e p ipes.
16.6.3 .2 Valves and Specialt ies
(a ) Valves & Specialt ies shal l be u sed t o star t, stop or regulate t he f lo w . Al l valves/special i t ies below
50 mm size ( for isolat ion purpose) in service water/dust suppression/potable water l ines should
be p lug type o f p roven make.
(b ) All valves shal l be sui table for most str ingent service condi t ions i .e. f low, temperature and
pressure under w h ich they m ay be requ i red t o opera te .
(c ) Gate/ slu ice valves shal l be u sed fo r isolat ion of f low of p ipe l ines above 50 NB and Globe valves
shall be used fo r regulat ing the f low .
(d ) Valves shal l be provided with back seating bush to faci l i tate gland renewal dur ing fu l l open
opera t ion .
(e ) All gate and globe valves of size 65 N B and large shal l be bo l ted b onn et, out side screw, r is ing type
w ith f langed ends. Valves of size 50 NB and smal ler shall be w ith screw ed end s.
(f ) Valves shal l be pro vided w ith t he fo l low ing as necessary:i. Hand wh eel
ii . Posit ion indicato r
iii. By-pass valve and spur gear reduct ion un i t fo r larger valves.
iv . Draining arrangement.
(g ) M ater ia l of construct ion of valves shal l not b e infer ior to t hose given in data sheet of th is sect ion.
(h ) Globe va lves sha ll be p rov ided w i th contou red p lug t o have w e l l contro l lab i li ty .
(i ) Non-return valves shal l be swing check type. These valves wi l l have a permanent ‘arrow’inscr ip t ion on i ts body to ind ica te d i rect ion o f m ot ion o f th e f lu id .
(j ) All valves shal l be provided with hand wheel, chain operated, extension spindle and f loor stand
w herever requ i red so t ha t t hey can be easi ly opera ted e i ther a t a low er or h igher e levat ion as the
case m ay be.
(k ) Strainer shal l be of du plex type d esigned w ith 3 w ay valves so t hat o ne f i l ter can be cleaned w hi le
the other is in operat ion. Sui table vent and drain valves shal l a lso be provided. Screen opening
area shal l be at least fou r t imes th e p ipe cross sect ional area. Pressure d rop in clean condi t ion s
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 49 of 66
The air quanti ty for mechanical venti lat ion system shal l be est imated based on equipment and
solar heat loads and the temperature r ise inside the bui ld ing. Necessary air f i l ters shal l be
pro vided t o supply o nly clean air int o b ui ld ing. Exhaust a ir shal l be d ischarged at a sui table height
above bui ld ing. Exhaust fans shal l be provided for Toi lets, Battery rooms. Al l undergroundstructu re shall be pr ovided w ith supply a ir as wel l as exhaust a ir fans.
17.2.2 Pressurised Ven tilat ion System
The pressur ised venti lat ion system having adequate nos. of supply and exhaust a ir fans with
washable metal l ic pre f i l ters, HDPE f ine f i l ters, and exhaust fans with sel f c losing f laps, duct ing
along with 3 phase AC motor dr ives, e lectr icals, support ing structures, access / maintenance
platfo rm s shal l be provided in a l l M CC/ sw itchgear room areas of coal handl ing plant t o be
furnished under th is speci f icat ion. The pressur ized venti lat ion system shal l be designed
consider ing 20 air changes per hour to maintain these areas pressur ised sl ight ly above
atm ospher ic p ressure t o p revent ingress o f du st f rom out side .
17.2.3 Air Condit ioning System
Air cond i t ion ing system sha l l be fu rn ished fo r contro l room area o f Wagon t ipp le r contro l
bui ld ing, i t shal l be designed consider ing the equipment heat loads, solar heat loads, heat gain
in to the room , adequate no. o f a i r changes e tc . to main ta in a un i fo rm tem pera ture and re lat ive
hum id i ty w i th in th e a ir cond i t ioned areas.
17.3 SCOPE
17.3 .1 M echanica l Vent i la t ion System
The venti lat ion system general ly consist ing of adequate number of supply and exhaust a ir fans,
air f i l ters, duct ing along with 3 phase AC motor dr ives, e lectr icals, support ing structures,
approach/maintenance platforms, civ i l and structural works and necessary accessor ies shal l be
furn ished fo r vent i la t ing the WT hopper , underground por t ion o f t ransfer po in ts , underground
conveyor t unn els and p ent h ouses. Exhaust fans shal l be provid ed for Toi lets & Batt ery room s.
17.3.2 Pressurised M echanical Ven tilat ion System
The venti lat ion system general ly consist ing of adequate number of supply and exhaust fans,
metal l ic pre f i l ters, HDPE f ine f i l ters, duct ing along with 3 phase AC motor dr ives, e lectr icals,
support ing structures, approach / maintenance platforms, necessary shed, civ i l & structural
w orks and necessary accessor ies shal l be fu rnished for a l l M CC/ sw itchgear room s.
17.3.3 Air Condit ioning System
17.3.4 2x100% capaci ty a ir condi t ion ing un i ts shal l be pro vided for W agon Tippler Cont rol Room .
17.3 .5 Supp ly and re turn a i r d ist r ibu t ion duct ing com ple te wi th insu la t ion , o f resin bonded m ineral woo l
equ iva len t o f dens ity a t least 24 Kg/m ³ and th ermal conduct iv ity o f m ax. 0 .49 m w / cm°C
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 51 of 66
17.5.6 Axial Fans
17.5 .7 Design dut y po in t o f the fan sha l l mat ch wi th the average va lue o f m aximum and m in im um f low
ra tes o f the fan in the stab le opera t ion zone. The speed o f th e fan shal l no t exceed 960 rp m forfan w i th impe l le r d iame te r above 450 mm and 1440 rpm fo r fan w i th impe l le r d iame te r 450 m m
and less. The f i rst cr i t ical speed o f ro tat in g assemb ly shal l be at least 25% abo ve operat ing speed.
17.5.8 Imp el lers shall be axial f low t ype single piece.
17.5.9 Cent rifugal Fans
17.5.10 The fan uni ts shal l be centr i fugal type with radial b laded impel ler . For design purpose out door
amb ient tem peratu re shal l be t aken as 50 deg.C.
17.5.11 Fans shal l be m anufactu red vibrat ion free in o perat ion and shal l be d esigned to l imi t n oise level
w i th in l imi ts speci f ied in Data Sheet.
17 .5 .12 The m oto r sha ll be ra ted fo r cont inuous opera t ion and conform to companion e lect r ica l
spec if ica t ion . How ever , mo tor ra t ing sha l l no t be less than the max. pow er demand th roughout
the ent i re range o f opera t ion o f f an .
17.5.13 Al l fan mo unt ings shal l have adequat e arrangement f or vibrat ion isolat ion.
17.5.14 The reverse f low th rough no n-w orking fan shal l be prevente d by dam pers. The dampe rs shal l bem ade out o f 18 SWG M S sheets.
17 .5 .15 Design du ty po in t o f th e fans sha l l match wi th the average va lue o f m aximu m and m in im um f low
ra te o f the fan in the s tab le operat ion zone.
17.5.1 6 Filters
17.5.16.1 M etal l ic Fi l ters
M etal l ic cleanable f i lters shal l be provided as requ ired. M ax. a ir veloci ty con sidered shall be 2
m/sec .
17.5.16.2 HDPE Filter s
HDPE f i l ters shou ld have an ef f ic iency of 90% dow n t o 5 m icrons. Velocity across the f i l ter shal l be
l im i ted to 2 .5 m/ sec.
17.5.17 High eff ic iency f i l ter ( for A/ C purp ose). Fi l t rat ion eff ic iency shal l not be less than 99.9% do wn to 5
m icrons. Pr. d rop across the f i lte r u nder c lean cond i t ion sha l l no t be m ore than 10 m m w .c.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 52 of 66
17.5.1 8 Packaged Air-Con dit ioning Un it
PAC uni ts shal l be p rovided as required.
17.5.19 PAC uni ts shal l be factory tested and assembled sel f contained uni ts complete wi th refr igerant
com pressor, coi ls, fans, insulat ion and w ir ing. Var ious parts of PAC un i ts wh erever requ ired shal l
be in su la ted w i th expanded po lyethy lene conform ing to IS:4671.
17.5.20 The PAC uni t shal l comprise of an evaporator ( indoor a ir ) b lower sect ion and an air cooled
condenser (outdoor a ir ) sect ion. Heavy gauge steel cabinet factory f in ished with two coats of
epoxy paint o f appro ved colour, shal l be used to hou se comp onent s of PAC.
17.5.21 The evaporator and cond enser coi ls shal l be arranged fo r d irect expansion cool ing and shal l be
formed of a luminum f ins mechanical ly bonded to seamless copper tubes and electr ical ly t inned.The inter-connecting refr igerant ci rcui ts shal l comprise of mult ip le cyl inder hermetic
compressor(s) and motor(s) wi th a l l necessary isolat ion valves, suct ion gas control led thermal
expansion valves, w i th adjustable set p oint , s ight g lass, copper tub ing and p ipel ine anci llar ies. The
condenser coi ls shal l be air cooled by propel ler type fans complete wi th safety guards. The
condensing coi ls shal l be sui tably arr anged to avoid radiant h eat p ick-up fro m solar sources.
17.5.22 Cond enser capaci ty cont rol shall be p rovided b y m eans of var iable speed f ans and ‘h ead pressure ’
sensing.
17.5.23 The evaporat or a ir b low er(s) shal l be cent r i fu gal forw ard curved t ype bel t d r iven by individualm oto r(s) and sui table f or t he ext ernal stat ic pressure . The f an assem bly shall be isolated from the
casing by anti -v ibrat ion mounts. The fan/motor dr ive shal l be capable of capaci ty adjustment by
pu l ley changes w ith in +15% of d esign dut y.
17.5.24 High eff ic iency f i lters shal l be pro vided in t he m ain supp ly a ir du ct and in t he fr esh air connect ion
to re tu rn a ir duct .
17.6 Construct ion Requirem ent s
17.6.1 General construct ion detai ls of var ious equipment under Contractor ’s scope shal l be aselaborated in subsequent clauses below .
17.6.2 Roof Venti lato rs and accessor ies
Roof vent i lators and accessor ies shal l be p rovided as required.
17.6.3 Imp el ler shal l be axia l f low type, cast in on e piece f in ished al l over and careful ly dynam ical ly
balanced after f inal assembly. Al l impel lers shal l consist of h igh eff ic iency aerofoi l b lades.
Impe l le rs shal l be mou nted d i rect ly on t he m otor shaf t .
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 53 of 66
17.6.4 Casing shal l be of h eavy gauge con struct ion and shal l be prope r ly re infor ced for r ig id i ty. Access
doo r w i th sui table locking arrangem ent shall be pro vided.
17.6.5 Hood shal l be of h inged type pro vid ing easy access to m ot or and imp el ler . It w i l l a lso prot ect
them f rom ra in and any o t her cont ingencies. W eather -proof lockab le typ e d isconnect swi tch sha llbe prov ided such tha t the hoods can be opened on ly when the d isconnect swi tch is in ‘OFF’
posi t ions. On larger sizes of roof venti lators, hoods shal l be of spl i t construct ion. 15 mm mesh
galvanised b ird screen shal l be pro vided. The hood s wi l l have low pre ssure d rop across i t .
17.6.6 Sui tab le arrangement shal l be provided fo r mo unt ing th e roof venti lato rs such that ingress of
ra inwater in t o th e bu i ld ing w i ll be avo ided comple te ly .
17.6.7 Axial Flow Fans
Axial f low fans shal l be pro vided as required.
17.6.8 Im pel lers shal l be axia l f low typ e and single piece cast a luminum w ith aerof oi l b lades construct ion .
I t shal l be f in ished al l over and balanced dynamical ly. Impel ler shal l be mounted direct ly on the
m o to r shaf t .
17.6.9 Casing shal l be of heavy gauge construct ion p roper ly re info rced for r ig id i ty. It shal l be pro vided
w ith sui table suppo rts. Access door shal l be pro vided in t he casing for easy access to m oto r and
imp el le r . Su i tab le ar rangem ent fo r m ount ing o f m otor sha l l be prov ided.
17.6.10 Rain protect ion cowls wi l l be designed to sui t wal l exhausters/supply fans for protect ing
fans/ m oto rs f rom ra in . I t w i ll be prov ided w i th b i rd screen.
17.6.11 In let con e or bel l and ou tlet cone shal l be provided as required. I t should b e made o f G.I. or M .S.
17.6.12 Motor shal l be of tota l ly enclosed type complying with the companion electr ical speci f icat ion.
Sui tab le ra in/ sun shade fo r m oto rs shal l a lso b e provided .
17.6.1 3 Cent rifugal Fan
Cent r i fugal fans shal l be p rovided as required .
17.6.14 The casing shal l be of w elded construct ion fabr icated w ith h eavy gauge m ater ia l . It shal l be r ig id ly
reinforced and supported by structural angles. The seams shal l be permanently sealed air t ight.
Split casing shall be provided on larger sizes of fans. Casing drain with valves shall be provided
w herever requ i red .
17.6.15 The im pel ler shal l have die for med curved blades fabr icated out of M S heavy gauge we lded to the
r im and back plate to have a non over load ing character ist ics of t he fan . Rim shal l be spun to h ave
a sm oot h cont our. I f requ ired interm ediate st i f fening r ings shal l be required. The im pel ler , pu l ley
and shaft s leeves shall be secured to th e shaft by key and/ or n ut s. The im pel ler a long wit h d r iven
pu l ley shal l be dyn amical ly balanced. Fan shaft shal l be o f EN-8 equ ivalent .
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 59 of 66
c) Supp ort ing Trest les
Intermediate trest les shal l be two legged and shal l del iver loads from gal lery trusses to thefoundations. In addi t ion, four legged trest les shal l be provided which wi l l act as f ixed support to
tran sm it a l l longi tu dinal forces bet w een expansion block, in addi t ion t o ot her for ces.
d ) Junction Houses
i) Floors - Floor beam layout shal l be arranged to sui t equipment layout as wel l as equipment
anchor ing system .
i i ) Columns - In addi t ion to loads from f loor and roof, columns shal l be designed to transmit
hor izonta l load due to be l t t ens ion / snapp ing o f be l ts to t he foundat ion .
e) Belt Tensioning Device
Suitable structures shal l be provided to accommodate bel t- tensioning device which may be
located ei ther un der th e conveyor gal lery or in th e junct ion hou se i tself .
f ) Wall Structures
(i ) Wall runners wi th necessary sag rods shal l be provided to support wal l sheeting in
conveyor galler ies and ju nct ion hou ses.
(ii) Walls shal l be provided with louvers and translucent sheeting at appropr iate levels, to
prov ide natu ra l vent i la t ion and l igh t ing .
g) Access stairs, w alkways, p latfo rm s, ladders, hand rai l ing et c.
(i ) W herever p ossib le, access shal l be p rovided by m eans of sta irs.
(ii) Al l w a lkways and s ta irs lead ing to wo rk ing p la t fo rm s sha l l have m in im um 800 m m w id th o f
w a lkw ays/ f l igh t o f sta i r .
(iii) All ot her w alkways and stairs leading to areas for m aintenance purpo se, or du e to restr ict ion
of space, sha l l have a m in imu m w id th o f 800 m m of w a lkway/ f l igh t o f s ta i r , un less requ i red
otherwise .
(iv) Staircases shal l be general ly designed w ith slope o f appro ximate 37.5° w ith th e hor izon tal .
( In no case the slope shal l exceed 40 ° with the hor izontal) . Intermediate landings shal l be
provided wherever required such that vert ical r ise of each f l ight does not exceed 3000mm.
Risers in on e fl ight shall be equa lly spaced.
(v ) Walkway f loors and stair treads shal l be designed with chequered plate (or non-sl ip type
plates). Ribbed f loor/treads may be provided wherever the possibi l i ty of accumulat ion of
dust exists, taking care that such provisions do not crate a nuisance to the operat ing
personne l on t he shop f loor .
(vi) Rise o f t reads in sta ircases shal l no t exceed 200 m m .
(vii) A min imum headroom of 2200 mm sha l l be prov ided over opera t ing p la t fo rms, v is i to r 's
gal ler ies, or oth er areas w ith po ssib i l i ty of p ubl ic gather in g. In a l l other p latfo rm s, w alkways
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 60 of 66
and stairs, minimum headroom of 2000 mm shal l be provided. Only in special cases, local
headroom o f 1800 mm may be a l low ed ( i.e . a t in te rsect ion w i th s t ructura l mem bers etc . ).
(viii) Cat ladders shal l be p rovided for access, w herever p rovision o f sta ircase is imp ract ical due to
l imit at ions of space, or t he access is required very infreq uent ly.(ix) W herever th e height of cat ladder exceeds 4.0 m , safety cage shal l be provided. Interm ediate
landing shal l be provided to cat ladders such that vert ical height of s ingle r ise does not
exceed 8.0 m .
(x ) Cat ladd ers shal l be d esigned w ith fo l low ing provisions:
i. Wid th o f r ung = 500 mm
ii . M in imum r ise o f rung = 250 mm ; Maximum r ise o f rung = 300 mm
iii. M inim um clearance from rung of ladd er to ba ck of cage (in case of caged ladders) =
700 mm
iv . M in imum c learance f rom the centre o f cage a l l round = 350 m m
v. Slope of cat- ladder s:
I . For no rm al cat- ladders, slope shal l be w ith in the range of 75°-90° w ith t he ho r izont al .
I I . For ship- type ladders ( i.e cat- ladders w i th shor t s ide h andrai ls) th e slope shal l be w ith in
th e range of 65°-75° w ith th e ho r izon tal .
(xi) All walkw ays, p latfor m s and stairs shall be p rovided w ith safety h andrai ls. Al l handrai ls shal l
be constructed with steel tubes / angles for posts, top and middle ra i l and plates/sheets for
to e plates. In case of sta irs, th e to e guards need no t b e provided .
(xii) The vert ical height of hand-rai l ings on walkways and stairs shal l be minimum 1000 mm
above f loor level.
(xiii) Hand-ra i ling a long edge o f roo f and gut t e rs sha l l have a m in imum he ight o f 600 m m over top
edge of gutters/sheets. In such hand rai l ings toe guards need not be provided. (Only top
handrai l and m idrai l shall be pro vided).
18.3 AD DITIO NA L DESIGN CRITERIA
a) Design of steel structu res shal l be don e in accordance w ith IS:800-1984.
b) In absence o f spec if ied dynamic factor to be cons idered fo r the load f rom t he be l t conveyor ,
a dynamic factor of not less than 1.3 shal l be considered for the design of f loor beams and
gallery girders.
c) Gallery trusses and str ingers as w el l as f loor beam s of junct ion hou se shal l be checked forobviat ing occurrence of resonance and shal l be designed such that the rat io of appl ied
f requency to na t ura l f requency sha l l no t l ie w i th in the range 0 .7 to 1 .5 .
d) As far as po ssib le gal lery str uctu re shal l be m ade independ ent of junct ion houses. A trest le
shal l be planned close to the junct ion house to avoid gal lery span rest ing on the junct ion
house.
e) The contractor a f te r the award o f wor k sha l l subm i t design cr ite r ia to owner / consu l tan t fo r
appro val before subm ission o f design draw ings.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 61 of 66
f ) The design drawin gs shal l be subm itte d in comp lete for a uni t a long w ith design calculat ion s
bot h in hard cop y and soft copy. Design shal l be d one u sing STAAD.
g) The effect ive rat io o f ut i l i ty of a l l main sect ion s shal l be l imi t ed to 0 .85
h) Struct ural schem atic general arrangement w i th p lans at var ious levels, e levations along each
row and axes, sect ion s, considered loads and load d iagram s with location et c. and Structu ral
design draw ings w ith BOQ and Table of m emb ers contain in g design fo rces shal l be subm itted
for Owner ’s/Consul tant ’s approval . However the approval shal l be l imi ted to checking of
overal l d imen sions, general stabi l i ty of system , effect ive load transfer and def lect ion l imi ts etc.
The approval shal l not re l ieve the contractor of h is responsibi l i ty of correctness in design,
adequacy of connection s, accuracy etc.
i ) Submission of Stabi l i ty cert i f icate for a l l the steel structures is under the scope of the
contractor .
18.4 Descript ion of loads and loading codes
a) Unless speci f ied o the rw ise hereinaft er , a l l the l ive loads shal l be con sidered in accord ance
w ith IS: 875 (Part-2) -1987.
b ) W ind loads shal l be con sidered in accordance w ith IS: 875 (Part-3)-1987.
c) Seism ic loads shal l be con sidered in accordance w ith IS:1893(part1)-2002 and 1893 (part 4)-
2005
d ) Live loads from conveyor o n t he gal lery f loo r shal l be as per conveyor suppl iers load data.e) W hile designing the f ixed supp ort / r ig id trest les in an expansion block of con veyor gallery the
fol low ing loads (in addi t ion to w ind load) shal l be considered.
(i ) Forces due to di f fe rence in fr ict ional resistance of to p and ret urn id le ro l lers of con veyor.
(ii) Forces due to iner t ia o f ro l le rs a t th e t ime o f s ta r t ing o f conveyor be l t .
(iii) Break dow n load caused by snapping of b el t ( in case of m ult ip le conveyors, snapping of
on e bel t at a t im e) shal l be considered.
(iv) Special load s if any
f ) Gallery g irders and f loor shal l be designed for the fo l lowing l ive loads,inclusive of spi l lage
loads on f loor s.i ) Walkway/Suppor t ing beams for f loor - 4 .0 KN/ m ²
i i Und er the conveyor be lt - 0 .75 KN/ m ²
i i i ) Gallery g irder, for f loo r load of - 3.0 KN/ m ²
g) Dust load on roof o f junct ion hou se and conveyor galler ies shall be consider ed as fo l low s:
i. For bu i ld ing and s t ructures loca ted a t a d is tance o f 300m f rom the du st p roduc ing
un i ts - 0 .5 KN/m ²
ii . At a d istance o f 300 m to 800 m f rom the dust p rodu c ing un i t - 0 .25 KN/ m ²
h ) As per technological requirements, provision of support ing the fo l lowing, and load ar is ing
th ereof shal l be considered in th e design o f conveyor gal lery.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 62 of 66
i ) Venti lat ion du ct.
i i) Electr ical cables/cable racks.
i i i) Fire Fighting equ ipm ent.
i) Jun ction hou se f loors shal l be designed for th e fo l low ing loads:i ) Live load on f loor - 5.0 KN/ m ²
i i ) Tension fro m con veyor bel t
i i) Load due t o equ ipm ent loca ted on f loor .
iv ) Load du e to jamm ing o f chutes.
v) Erect ion loads anyw here on t he f loor.
j ) Comb inat ion o f loads
The var iou s loads speci f ied shal l be com bined in accord ance w ith clause 8.0 of IS: 875 (Part-
5)-1987 to give the m ost severe loading cond i t ion fo r design of structu res.
k) Str ess enhancem ents
Permissib le l imi ts of stress may be increased, wherever permissib le, in accordance with
IS:800-1984.
18.5 Limit ing def lect ion
a. The deflect ion shal l be l imi ted in var ious elements of structures in accordance with clause
3.13 IS: 800 -1984.
b . In addi t ion f o l low ing limit at ion in deflect ion shal l be observed in design:
i) Gallery Trusses Span / 400
i i ) Top of End po r ta l of gallery tru ss H / 325 wh ere H =Height of po r ta l above beam s
i i i ) Traverse def lect ion of top of Trest le H/ 1000 w here H = Height of t rest le above foun dation
18 .6 FABRICATI ON OF STEEL STRUCTURES
18.6 .1 Drawings
The Contractor shal l prepare fabr icat ion drawings, erect ion drawings, b i l l of mater ia ls, drawingoff ice despatch l ists / shipp ing docum ents, schedule of b ol ts and nu ts and as bui l t draw ings. Al l
draw ing wo rk shal l be in m etr ic system and al l w r i t ing w ork shal l be in English. The wo rk shall be
carr ied ou t as descr ibed in General Technical Speci f icat io ns for stru ctural w orks.
18.6 .2 M ater ia l of Construct ion
18.6.2.1Al l steel and o ther m ater ia ls used for steelw ork and in associat ion w ith steelw ork shal l confo rm
to appropr iate Indian standards. Only tested mater ia ls shal l be used unless wr i t ten author i ty is
obta ined fo r th e use o f un t ested mat er ia ls fo r cer ta in secondary s t ructura l mem bers.
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 64 of 66
18.6.2.14 Cert i f ied m i l l test repo rts of m ater ia ls used in the w ork shal l be mad e available for
inspect ion b y the Ow ner / Consu l tan t upon r equest .
18.6.3 Fabricat ion
18.6.3.1 Fabr icat ion of a l l structural steelwork shal l be in accordance with IS:800 or their equivalent
foreign national standard of the country of or ig in of supply unless otherwise speci f ied, and in
confo rm ity w i th v ar ious clauses of th e Technical Speci f icat ion .
18.6.3.2 W herever pract icable and wh erever perfect match ing of part s is required at si te, m emb ers shal l
be shop assembled before despatch to minimise si te work. Parts not completely assembled in
th e shop shal l be secured, to t he exten t po ssib le, to p revent dam age du r ing despatch.
18.6.3.3 ERECTION OF STEEL STRUCTURES
18.6.3 .3.1 Scope
The scope o f work under erect ion inc ludes in add i t ion to prov is ion o f e rect ion and t ranspor t
equipm ent s, too ls and tackles, consum ables, mat er ia ls, labou r and super vision, the fo l low ing:
a) Stor ing and stacking at si te of erect ion of a l l fabr icated structural components/ uni ts/assembl ies
t i l l the t ime o f e rect ion .
b ) Transpo rtat ion of stru ctures at si te.
c)
Receiving at si te of structur es including site hand l ing /m ovem ent , unloading, stor ing and stackingat si te of erect ion o f techno logical stru ctures such as bun kers and t he re lated struct ures
d ) Al l m inor r ect i f ica t ion / m od i f ica t ion such as :
i ) Rem oval of b ends, kinks, tw ists, etc. for part s dam aged du r ing transport at ion and hand l ing;
i i ) Cutt ing chipping, f i l ing, gr inding, etc., i f required, for preparat ion and f in ishing of si te
connections;
i i i ) Ream ing for use of n ext h igher size bol t f or ho les w hich do no t register o r w hich are damaged.
iv) Welding of connections in p lace of bol t ing for which holes are ei ther not dr i l led at a l l or
w rong ly dr i l led dur ing fabr icat ion .
e) Other rect i f i ca t ion w ork such as
i) Re-fabr icat ion of parts, damaged beyond repair dur ing transportat ion and handl ing orincorrect ly fabr icated.
i i ) Fabr icat ion of par ts om itte d dur ing fabr icat ion b y oversight or subsequent ly found n ecessary.
i i i ) Plug-welding and re-dr i l l ing of holes which do not register and which cannot be reamed for
use of n ext h igher size bol t .
f ) Fabr ica t ion o f minor i tems/miss ing i tems or such impor tan t i tems as d i rected by the Owner /
Consul tant.
g) Assemb ly a t s i te o f s teel s t ructura l component s wherever requ i red inc lud ing t empo rary suppor t s
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 65 of 66
h ) M aking arrangem ents for and provid ing al l facil i t ies for conduct ing ul trasonic X-ray or gamm a ray
tests on w elds; gett ing th e tests condu cted by reput ed test ing laborato r ies, m aking available test
f i lm s/ g raphs,repor ts and in t erpre ta t ion .
i) Rect i fy ing a t si te , damaged por t ions o f shop pr im er by c lean ing and t ouchup pa in t . j ) Erection of structures including making connections by bol ts/h igh strength fr ict ion gr ip bol ts /
we ld ing .
k) Al ignment o f a l l s t ructures t rue to l ine , leve l p lumb and d imensions wi th in spec i f ied l imi ts o f
to lerances as per IS :12843 “ Tolerance fo r Erect ion of Steel Stru cture s” .
l) Appl ica t ion o f second coat o f p r imer pa in t and tw o coats o f f in ish ing pa in t a t s ite a f t e r e rect ion .
m ) Grout ing o f a l l co lumn bases a f te r p roper a l ignment o f co lumns and on ly a f te r ob ta in ing
c learance f rom Own er / Consu l tan t .
n ) Condu cting prel im inary acceptan ce and f inal accepta nce tests.
o ) Preparat io n of as bui l t dr awings, prepar ing of sketches/d raw ings to sui t
f ie ld engineer ing decisions, avai labi l ity of m ater ia l , convenience of fabr icat ion, t ransportat ion and
erect ion and changes du r ing fabr icat ion and erect ion.
A l l such w orks are sub ject to approva l by t he Ow ner / Consu l tan t .
18 .6.4 PAINT ING O F BUI LDIN G STEEL STRU CTURES
18.6.4.1Al l steel structural work shal l be painted as fo l lows unless otherwise stated in the drawing /
Technical Specification .
18.6.4.2 Surface preparat ion
The steel surface wh ich is to be paint ed shal l be cleaned of d ir t and grease, and the h eavier layers
of ru st shal l be rem oved b y chipping pr ior to actua l surface preparat ion t o a speci f ied grade.
Fo l lowing are the type and s tandards o f sur face prepara t ion to be fo l lowed based on the
requ iremen t o f a part icular paint ing system or as speci f ied in th e design draw ings.
M anual/ Pow er to ol c leaning :- M anual/ Pow er to ol c leaning shal l be done as per Grade St-2 or St-3
of Sw edish Standard Inst i tu t ion SIS 05 5900 or cl .6.2.1.1 & 6.2.1.2 of IS : 1477 - 1987 (Part - 1) .
Grade St-2 :- Thor ough scraping and w ire bru shing, m achine brushing, gr inding etc. This grade ofpreparat ion shal l rem ove loo se mi l l scale, rust cleaner or w i th clean com pressed air or clean bru sh.
After preparat ion, th e surf ace shou ld have a fa int m etal l ic sheen. The appearance shal l correspond
to t he pr in ts designated St-2. I f no grade of surface preparat ion is speci f ied, St-2 grade o f
preparat ion as per Swed ish Standard shal l be fo l low ed.
18.6.4 .3 Paint System
(i ) Sur face preparat ion :- St -2
(ii) Pr imer pa in t : - Tw o coats o f z inc phosphate in pheno l ic a lkyd m edium (35m icrons/coat) .
(iii) Finishing paint:- Two coat s of synth etic enam el (25 m icrons/coat ) confo rm ing to IS : 2932
Technical Specification: System Param ete rs, Operat ion & Cont rol Philosophy Page 66 of 66
All paints shal l be of app roved and shade as per Purchaser / Consul tant 's requiremen ts.
18.6 .4 .4 Paint and Paint ing
M anufactu re of paint s, m ixing of paint s, etc. shall be general ly accord ing to th e re levant IS codes
of pract ice.
General ly compatib i l i ty between pr imer intermediate and f in ishing paint shal l be cert i f ied by the
pa in t m anufacturer supp ly ing the pa in ts .
Guarantee per iod sha ll comm erce f rom the date o f comp le t ion o f f in ish ing coat o f pa in t on ent i re
structu res. The guarantee p er iod shall be indicated depending on t he type o f surface preparat ion
and system o f p a in t ing . To fu l f i ll th is ob l iga t ions, the Contractor may ob ta in f rom the pa in t ing
m anufacturer , guarantee fo r the p er fo rmance o f pa in t / pa in ted sur faces.
Appl icat ion o f paint shal l be by spraying or b rushing as per IS : 486-1983 and IS : 487-1985 and in
un i form layers of 50% over lapping stro kes by ski lled painters. Paint ing shal l not b e done w hen t he
tem peratu re is less than 5 degree C or m ore th an 45 degree C and relat ive hum idi ty is mor e than
85% unless manufacturer 's recommendations permit. Also paint ing shal l not be done in foggy
weather. Dur ing appl icat ion, paint agi tat ion must be provided where such agi tat ion is
recom mended by the manufacturer .
Paint ing shal l be appl ied at paint ing manufacturer 's recommended rates. The number of coats
shall be such that m inimu m dry f i lm t h ickness specif ied is achieved. The dry f i lm th ickness (DFT)of p aint ed surfaces shall be checked w ith ELCOM ETER or m easur ing gauges t o ensure specified
DFT.
Al l structures shal l receive one coats of pr imer paint at shop after fabr icat ion before despatch
af te r sur face prepara t ion has been done as per r equ i rements.
Unless oth erw ise speci f ied al l str uctu res after er ect ion shall be given on e coat of p r imer and tw o
coats of f in ishing paint of appr oved colour and qual i ty. The und er coat shal l have di f f erent t int t o
dist inguish th e sam e from th e f in ishing coat.
The propo sed m ake, quali ty and shade o f paint shal l have the approval of Purchaser / Consul tant.
Technical Specificati ons: Genera l Technical Requirem ents Page 1 of 29
SECTIO N 5
1.0 INTRODUCTION
This part covers technical requirements which wi l l form an integral part of the Contract. The
fo l low ing prov isions sha l l supp lement a l l the deta i led techn ica l requ i rements brought ou t in th e
Technical Specification s and th e Techn ical Data Sheet s.
2 .0 B RA N D N A M E
Whenever a mater ia l or ar t ic le is speci f ied or descr ibed by the name of a part icular brand,
m anufacturer o r vendor , the speci f ic i tem m ent ioned shal l be understood to be ind icat ive o f th e
funct ion and qua l i ty des i red , and not rest r ic t ive ; o ther manufacturer 's p roducts may be
considered prov ided su f f ic ien t in fo rmat ion is fu rn ished to enab le the Employer to de termine
that the p roducts proposed are equ iva len t to t hose nam ed.
3.0 COM PLETENESS OF FACILITIES
3.1 Cont ractors m ay not e that th is is a cont ract inclusive of the scope as indicated elsew here in the
speci f icat ion. Each of the plant shal l be engineered and designed in accordance with thespecif icat ion r equirem ent. Al l engineer ing and associated services are required to ensure that a
comple te ly eng ineered p lan t is p rov ided.
3.2 Al l equipm ent s fur nished by the Con tracto r shal l be com plete in every respect, w i th a l l
mountings, f i t t ings, f ixtures and standard accessor ies normal ly provided with such equipment
and/or those needed fo r e rect ion , comple t ion and sa fe opera t ion & main tenance o f the
equipment and for the safety of the operat ing personnel, as required by appl icable codes,
though they may not have been speci f ical ly detai led in the respective speci f icat ions, unless
included in the l ist of exclusions. Al l s imi lar standard components/ parts of s imi lar standard
equ ipment p rov ided, sha l l be in te rchangeab le wi th one anot her .
4.0 COD ES & STAND ARDS
4.1 In addi t io n to the codes and standards speci f ical ly m ention ed in the re levant technical
spec i f ica t ions fo r the equ ipment / p lan t / system, a l l equ ipment par ts , systems and works
covered under th is speci f icat ion shal l comply wi th a l l currently appl icable statutory regulat ions
Technical Specificati ons: Genera l Technical Requirem ents Page 2 of 29
d . Ind ian Explo sives Act
e. Ind ian Factor ies Act and St ate Fact or ies Act
f . Ind ian Boiler Regulation s (IBR)g. Regulat ions of t he Central Pol lut ion Contro l Board, India
h . Regula t ions o f t he M in ist ry o f Env ironm ent & Forest (M oEF), Governm ent o f Ind ia
i. Pol lu t ion Contr o l Regu la t ions o f Depar tm ent o f Env ironm ent , Government o f Ind ia
j. State Pol lut ion Cont rol Board.
k. Rules for Electr ical instal lat ion by Tar i f f Advisory Com m ittee (TAC).
l. Guidel ine fo r w agon t ipp le r – G33 Rev.01 o f M ay 2010.
m . Any oth er stat ut ory codes / standard s / r egulat ions, as m ay be app l icable.
4.2 Unless covered oth erw ise by Indian codes & standards and in case no thing to the contr ary is
speci f ical ly mentioned elsewhere in the speci f icat ions, the latest edi t ions (as appl icable as ondate o f b id op ening), of th e codes and standards given below shall a lso apply:
(a.) Japan ese Indu str ial Stan da rd s (JIS)
(b.) Am erican National Standard s Inst i tu te (ANSI)
(c.) Am erican Society o f Testing and M ater ia ls (ASTM )
(d.) Am erican So ciety o f M echanical En gineers (ASM E)
(e.) Ame rican Petro leum Inst i tu te (API)
( f .) Standard s of the Hydraul ic Inst i tu te, U.S.A.
(g.) Inter national Organisat ion for Standa rdizat ion ( ISO)
(h.) Tubu lar Exchanger M anufact urer 's Associat ion (TEM A)
( i .) Am erican W elding Society (AWS)( j .) Nat ional Electr ical M anufactu rers Associat ion (NEM A)
(k.) Nat ional Fire Pro tect ion Associat ion (NFPA)
(l.) Int erna tion al Electr o-Technical Com m ission (IEC)
(m .) Expan sion Join t M anu factu rers Asso ciation (EJM A)
(n.) Heat Exchange Inst itu te (HEI)
4.3 In th e event of any conf l ict bet we en th e codes and standard s referr ed to in th e above clauses
and the requirement of th is speci f icat ion, the requirement of Technical Speci f icat ion shal l
govern .
4.4 In case of any change in codes, standards & regulat ions bet w een th e dat e of b id open ing and
the date when vendors proceed wi th fabr ica t ion , the Employer sha l l have the opt ion to
incorpora te the changed requ i rements or to re ta in the or ig ina l s tandard . I t sha l l be the
responsibi l i ty of the Contractor to br ing to the notice of the Employer such changes and advise
Em ployer of t he resul t in g effect.
4.5 EQ UIPM ENT FUNCTIONAL GUARANTEE
The fun ct iona l guarantees o f t he equ ipm ent and the system under the scope o f the Contract is
given elsewhere in the technical speci f icat ion. These guarantees shal l supplement the general
pro visions covered u nder General Cond it ion s of Contr act.
Technical Specificati ons: Genera l Technical Requirem ents Page 5 of 29
v i . On comple t ion o f e rect ion , a com ple te l is t o f bear ings / equ ipment g iving the i r loca t ion , and
identi f icat ion marks etc. shal l a lso be furnished to the Employer indicat ing lubr icat ion
m ethod fo r each t ype/ca tegory o f bear ing .
4.8.3 Project Com plet ion Report
The Cont ractor sha l l subm i t a Pro ject Comple t ion Repor t a t t he t ime o f hand ing over th e p lan t .
4 .8 .4 D R A W IN GS
(a.) All documents submitted by the Contractor for Employer 's review shal l be in e lectronic
form (soft copies) a long with the number of hard copies. The soft copies to be suppl ied
shal l be ei ther in CDs, or through direct transfer via E-mai l , etc. depending upon the
nature / vo lume/ size o f t he docum ent . The drawings subm i t ted fo r approva l cou ld be in th e
Im age fo rm .
(b.) Final copies of the appro ved draw ings shal l be subm itted in vecto r form on CDROM along
w i th th e requ isi te num ber o f hard cop ies.
(c.) Al l docum ents/ text in fo rmat ion sha ll be in la test vers ion o f M S Off ice.
(d.) Al l d raw ings subm i t ted by the Contractor inc lud ing those subm i t ted a t the t ime o f b id sha l l
be in suff icient det ai l indicat ing the t ype, size, arrangemen t, w eight of each com pon ent fo r
packing and shipment, the external connection, f ix ing arrangement required, the
d imensions requ i red fo r ins ta l la t ion and in terconnect ions wi th o ther equ ipments andmater ia ls, c learance and spaces required between var ious port ions of equipment and any
oth er inform ation speci f ical ly requested in t he draw ing schedules.
(e.) Each drawing submitted by the Contractor ( including those of sub-vendors) shal l bear a
t i t le b lock a t the r igh t hand bot tom corner wi th c lear ment ion o f the name o f the
Employer, the system designation, the speci f icat ions t i t le , the speci f icat ion number, the
name of the Project, drawing number and revisions. I f standard catalogue pages are
subm itted th e appl icable i tem s shal l be indicated th erein. Al l t i t les, not ings, markings and
w ri t ings on th e draw ing shal l be in Engl ish. Al l the dim ensions shou ld be in m etr ic uni ts.
(f.) The drawings submitted by the Contractor (or their sub-vendors) shal l bear Employer ’s
drawing number in add i t ion to contractor ’s ( the i r sub-vendor ’s) own drawing number .
Emp loyer ’s drawin g num bering system shal l be m ade avai lable to th e successful Cont ractor
so as to enable him to assign Emp loyer ’s draw ing num bers to th e draw ings to be subm itted
by h im dur ing the course o f execut ion o f the Contract .
(g.) The Contractor shal l a lso furnish a “M aster Drawing List” w hich shal l be a com prehen sive
l ist of a l l drawings/ documents/ calculat ions envisaged to be furnished by him dur ing the
detai led engineer ing to th e Em ployer in l ine with en gineer ing inform ation f low schedule ( to
be t ied up with successful Contractor) . Such l ist should clear ly indicate the purpose ofsubm ission o f t he se dra w ings i.e. “FOR APPROVAL” or “ FOR INFORM ATION ONLY” .
Technical Specificati ons: Genera l Technical Requirem ents Page 6 of 29
(h.) Simi la r ly , a l l the drawings/ documents submi t ted by the Contractor dur ing deta i led
engineer ing stage shal l be stamp ed “ FOR APPROVAL” or “ FOR INFORM ATION” pr ior to
submission.(i.) The furnishing of detai led engineer ing data and drawings by the Contractor shal l be in
accordance w i th t he t im e schedu le fo r the pro ject . The rev iew o f t hese docum ents/ da ta /
drawings by the Employer wi l l cover on ly genera l conformance o f the data / d rawings/
documents to the speci f ica t ions and contract , in te r faces wi th the equ ipment s prov ided b y
others and external connect ions & d imensions wh ich m ight a f fect p lan t layout . The rev iew
by the Employer shou ld no t be construed to be a thorough rev iew o f a l l d imensions,
quanti t ies and detai ls of the equipments, mater ia ls, any devices or i tems indicated or the
accuracy o f the in fo rmat ion submi t ted . The rev iew and/ o r approva l by the Employer /
Project M anager shal l not re l ieve th e Cont ractor of any o f h is respon sibi l it ies and l iabi l i t ies
under t h is contract .
(j.) After the approva l o f the drawings, fu r ther work by the Contractor sha l l be in s t r ic t
accordance w i th t hese approved drawings and no dev ia t ion sha ll be perm i t ted w i thout the
w r i t ten approva l o f the Emp loyer .
(k.) Al l m anufactur ing , fabr icat ion and execut ion o f w ork in connect ion w i th th e equ ipment /
system, pr ior to the approval of the drawings, shal l be at the Contractor ’s r isk. The
Contractor is expected not to make any changes in t he des ign o f t he equ ipm ent / system ,
once th ey are appro ved by t he Em ployer. How ever, i f som e changes are necessi tated in the
design o f the equ ipment / system a t a la te r da te , the Contractor may do so , bu t suchchanges shal l prom pt ly be brought to th e not ice of t he Em ployer indicat ing th e reasons for
the change and get the rev ised drawing approved aga in in s t r ic t conformance to the
provisions of the Techn ical Speci f icat ion.
(l.) Draw ings shal l include al l instal lat ion s and det ai led p ip ing and w ir ing draw ings.
(m.) Assessing & ant ic ipat ing the requ iremen t and supply of a l l p ip ing and eq uipm ent shal l be
done by the contractor wel l in advance so as not to h inder the progress of p ip ing &
equipment erect ion, subsequent system charging and i ts effect ive drain ing & venting
arrangement as per site sui tabi l i ty.
(n.) Any so f tw are used b y th e contractor sha ll be g iven to the pro ject m anager and concerned
engineer of employer. The contractor shal l make the engineer of the employer aware of
the p rogram m e. Any com puter a ided pr ogramm e sha ll be approved sub ject to g iv ing ent i re
deta i l to the p ro ject m anager .
(o.) Drawings must be checked by the Contractor in terms of i ts completeness, data adequacy
and relevance wit h respect to Engineer ing schedule pr ior t o subm ission t o t he Emp loyer. In
case drawings are found t o be submi t t ed w i thout p roper endorsement fo r check ing by the
Contractor , the same sha l l no t be rev iewed and re turned to the Contractor fo r re -
Technical Specificati ons: Genera l Technical Requirem ents Page 7 of 29
submission. The contractor shal l make a visi t to si te to see the exist ing faci l i t ies and
understand the layout completely and col lect a l l necessary data / drawings at si te which
are needed as an input to the engineer ing. The contractor shal l do the completeengineer ing including inter facing and integrat ion of a l l h is equipment, systems & faci l i t ies
w ith in h is scope o f w ork as w el l as inter face engineer ing & integrat ion of system s, faci li t ies,
equipment & works under Employer ’s scope and submit a l l necessary drawings/
documents fo r t he same.
(p.) All drawings shal l be reviewed and approved by Engineer ing coordinator, including the
fo l lowing draw ings / da ta wh ich requ i re speci f ic approva l .
1 . Data sheets for var ious equipm ents / system s.
2 . Field test ing procedures for var ious equipm ent and p ip ing system .
3 . Pre commissioning / commissioning procedures including f lushing, Chemicalc lean ing, steam b lowing and hydro test e tc . (Wherever app l icab le) O&M manua l
shall a lso be review ed and appro ved by Em ployer. The cont ent o f O& M manu al shal l
be as speci f ied elsew here in th e speci f icat ion.
4 . Guarantee test pro cedures.
5 . Any o ther d raw ings tha t m ay be requ i red by the Eng ineer f rom t im e to t im e.)
6 . Data furnished in the bid shal l be binding on the contractor even i f super ior to the
techn ical speci f icat ion requirem ent and any revision shal l be don e w ith th e ow ner ’s
agreement .
(q.) The Contractor sha ll subm i t adequate pr in ts o f d raw ing / da ta / document fo r Emp loyer ’sreview and approval . The Employer shal l review the drawings and return one (1) copy to
the Contractor au thor izing e ither t o p roceed w i th m anufactur e or fabr ica t ion , o r m arked to
show changes desired. When changes are required, drawings shal l be re-submitted
promptly, wi th revisions clear ly marked, for f inal review. Any delays ar is ing out of the
fa i lu re o f the Contractor t o subm i t / rect ify and resubmi t in t ime sha l l no t be accepted as a
reason fo r delay in the cont ract schedule
(r.) Upon rev iew o f each drawing, depend ing on the cor rectness and comple teness o f the
drawing, the same wi l l be categor ised and approval accorded in one of the fo l lowing
categor ies :
CATEGORY I App ro ved
CATEGORY II Approved subject to incorporat ion of comments/ modif icat ion as noted.
Resubm i t rev ised d rawing incorpora t ing the Com ment s
CATEGORY II I Not ap proved. Resubm it re vised draw ings for appro val after incorporat ing
comm ents/m odi f ica t ion as noted.
CATEGORY IV For in fo rm atio n an d reco rds.
(s.) Vendor shal l resubmit the drawings approved under Category I I and II I wi th in three (3)
w eeks of receipt o f comm ent s on t he draw ings, incorpo rat ing all comm ents. Every revision
of t he d rawin g shal l bear a revision index w herein such revisions shal l be highl ighted in th e
Technical Specificati ons: Genera l Technical Requirem ents Page 8 of 29
fo rm o f d escr ip t ion or marked up in the draw ing ident i fy ing the same w i th re levant rev ision
Num ber en closed in a tr iangle (eg. 1, 2, 3 etc) .
In case Vendor does not agree with any speci f ic comment, he shal l furnish the
explanation for the same to owner / consul tant for considerat ion. In a l l such cases
vendor shal l necessar i ly enclose explanations along with the revised drawing ( taking
care o f ba lance comm ents) to avo id any de lay and/ or dup l ica t ion in rev iew w ork.
I t is responsibi li ty of t he Vendor t o get a l l the draw ings appro ved in th e Category I & IV
(as the case may be) and complete engineer ing act iv i t ies wi th in the agreed schedule.
Any delay ar is ing out of submission and modif icat ion of drawings shal l not a l ter the
contract complet ion schedule. Vendor shal l not make any changes in the port ions of
the draw ing o th er than th ose comm ented upon . If changes are requ i red t o be m ade inthe p or t ion s al ready approved, the vendor sha l l resubm i t th e drawing ident i fy ing the
changes for o w ner ’s review and approval .
(t.) I f Vendor fa i ls to resubmit the drawings as per the schedule, construct ion work at si te wi l l
no t be he ld up and work wi l l be car r ied out on the bas is o f comments fu rn ished on
previous issues of the draw ing. These com m ent s w i l l be taken care by the cont ractor w hi le
subm i t t ing th e rev ised draw ing.
(u.) All engineer ing data submitted by the Contractor after f inal process including review and
approva l by th e Pro ject M anager / Emp loyer sha l l fo rm par t o f th e contract do cument s and
the ent i re w orks covered under these spec if ica t ion sha l l be per fo rm ed in s t r ict conform i ty
w ith t echnical speci f icat ion s unless oth erw ise expressly requested by the Project M anager
in wr i t ing .
(v.) After f inal acceptance of individual equipment / system by the Employer, the Contractor
w i ll update a l l o r igina l d rawings and docum ents fo r th e equ ipment / system to “ as bu i l t ”
condi t ions.
4.8.5 ENGIN EERING INFORM ATION SUBM ISSION SCHEDULE
Prior t o t he aw ard of Cont ract, a Detai led Engineer ing Inform ation Subm ission Schedule shal l be
t ied up with the Employer. For th is, the Contractor shal l furnish a detai led l ist of engineer ing
information along with the proposed submission schedule. This l ist would be a comprehensive
one inc lud ing a l l eng ineer ing data / d rawings / in fo rmat ion fo r a l l bought ou t i tems and
m anufactured i tem s. The inform ation shal l be categor ised int o th e fo l low ing part s.
In format ion tha t sha l l be subm i t ted fo r the approva l o f the Employer be fore proceed ing fu r ther ,
and In format ion tha t wou ld be submi t ted fo r Employer ’s in fo rmat ion on ly . The Eng ineer ing
Information Schedule shal l be updated month wise. The schedule should al low adequate t ime
for p roper rev iew and incorpora t ion o f changes/ mod i f ica t ions, i f any, to meet the contract
Technical Specificati ons: Genera l Technical Requirem ents Page 10 of 29
f inal ised in th e above en gineer ing schedule, shal l be str ict ly adh ered t o. This is essent ia l for t he
t ime ly comp le t ion o f t he pro ject .
(b ) A detai led dr ive l ist shal l be furnished along wit h th e tende r. Furt her dr ive l ist shal l be subm ittedto the Eng ineering coord ina tor w i th in 60 days f rom the date o f aw ard o f t he contract .
(c ) In any case, in o rder to ach ieve the pro ject comple t ion dates, the contractor must s t r ic t ly
comp ly wi t h engineer ing schedules.
(d ) Final d istr ib ut ion copies of a l l appro ved drgs. ( in Cat. I & IV) shal l be subm itte d by t he cont ractor
to the Eng ineer wi th in tw o (2) weeks o f t he approva l.
(e ) Cop ies of a l l app roved d rgs. ( in cat. I & IV) shal l be subm itte d incorp orat ing al l si te m od if icat ions,
i f any, dur ing constru ct ion, erect ion, com m ission stages and perf orm ance and guarantee t est ing(t i l l i ts cont inuous op erat ion) as ‘As Bui lt Drgs’.
(f ) The cont ractor shal l use a single transm itta l f or drgs. Subm ission. This shal l include transm itta l
numbers and date , number o f cop ies be ing sent , names o f the agencies to whom are a l l the
copies being sent d rg. num bers and t i t les, remar ks or special notes i f any et c.
(g ) Al l m anufactur ing and fabr ica t ion wo rk in connect ion w i th th e equ ipment s pr io r to the approva l
of the drg. shal l be at contractors r isks. (h) Approval of contractor ’s drgs. or work by the
Engineer shal l not re l ieve the contractor of any of h is responsibi l i t ies or l iabi l i t ies under the
contract .
4.9.4 Erect ion Draw ings
(a ) Contractor shal l furnish erect ion drawings for the guidance of h is/ Employer ’s si te staff at
least 4 weeks before schedu led commencement o f e rect ion or the f i rs t sh ipment ,
whichever is ear l ier . These shal l general ly comprise of fabr icat ion/assembly drawings,
var ious com pon ent/ part detai ls draw ings, assemb ly, clearance, data requirem ent s etc. The
drawings sha l l conta in de ta i ls o f components / equ ipment wi th ident i f i ca t ion numbers,
m atch m arks, b i l ls of m ater ia ls, assem bly pro cedures etc.
(b ) For al l m ajor equipm ent apart from above detai ls, assemb ly sequence and instruct ion s w ith
check l ists shal l be fu rnished in t he f orm of erect ion m anuals CLAUSE NO.
4.9.5 ENGIN EERING PROGRESS AND EXCEPTION REPO RT
A report g iving the status of each engineer ing information including the l ist of
d rawings/ eng ineer ing in fo rmat ion wh ich rem ains unapproved fo r m ore than fou r (4 ) w eeks
af te r the date o f f i rs t submiss ion Drawings wh ich were not submi t ted as per agreed
Technical Specificati ons: Genera l Technical Requirem ents Page 11 of 29
4.9.6 TECHN ICAL CO-ORDIN ATION M EETING
(a ) The Contractor shal l be cal led upon to organise and attend monthly Design/ Technical Co-ord ina t ion M eet ings (TCM s) w i th t he ow ner / ow ner ’s representa t ives and o th er Cont ractors
of t he Em ployer dur ing the per iod of con tract. The Cont ractor shal l att end such m eetings at
his own cost as and when required and fu l ly co-operate wi th such persons and agencies
involved dur ing t he d iscussion s.
(b ) The Contractor shou ld no te t ha t T ime is the essence o f th e contract . In o rder to exped i te th e
ear ly complet ion of engineer ing act iv i t ies, the Contractor shal l submit a l l drawings as per
the agreed Engineer ing Information Submission Schedule. The drawings submitted by the
Contractor wi l l be reviewed by the Employer as far as pract icable wi th in three (3) weeks
from the date o f rece ip t o f the drawing .The comments o f the Employer sha l l then bediscussed across the table du r ing th e above Technical Co-ordinat ion M eeting (s) wher ein
best e f fo r ts sha l l be m ade by bot h s ides to ensure t he approva l o f t he draw ing.
(c ) The Contractor shal l ensure avai labi l i ty of the concerned experts / consul tants/ personnel
w ho are empo w ered to take necessary dec is ions dur ing th ese m eet ings.
(d ) Should any drawing remain unapproved for more than six (6) weeks after i t ’s f i rst
submission, th is shal l be brought out in the monthly Engineer ing Progress and Exception
Repor t w i th reasons thereof .
(e ) Any de lays ar ising out o f fa i lu re by the Contractor t o incorpora te Employer ’s com men ts and
resubm it t he same d ur ing th e TCM shall be considered as a defaul t and in n o case shall
en t i t le the Contractor to a l te r th e Cont ract com ple t ion date .
4.9 .7 DESIGN IM PROV EM ENTS
The Employer or the Contractor may propose changes in the speci f icat ion of the equipment or
qual i ty thereof and i f the part ies agree upon any such changes the speci f icat ion shal l be
modif ied accordingly. I f any such agreed upon change is such that i t affects the pr ice and
schedule of complet ion, the part ies shal l agree in wr i t ing as to the extent of any changing the
pr ice and/ or schedu le o f com ple t ion before the Cont ractor p roceeds wi th the change. Fo l low ing
such agreement , t he prov ision t hereof , shal l be deemed to have been am ended accord ing ly .
4.9.8 EQ UIPM ENT BASES
A cast i ron o r weld ed steel base plate shal l be pr ovided for a l l rotat ing equipm ent w hich is to b e
instal led o n a concrete b ase, unless oth erw ise specif ical ly agreed t o b y t he Employ er. Each base
plate which support the uni t and i ts dr ive assembly, shal l be of a neat design with pads for
Technical Specificati ons: Genera l Technical Requirem ents Page 14 of 29
4.10.2 Preservat ive Shop Coat ing
All exposed metal l ic surfaces subject to corrosion shal l be protected by shop appl icat ion of
sui table coatings. All surfaces which w i l l not be easi ly accessible aft er t he shop assemb ly, shal l
be t rea ted beforehand and pro tected fo r the l i fe o f the equ ipment . A l l sur faces sha l l be
thoroughly cleaned of a l l mi l l scales, oxides and other coatings and prepared in the shop. The
sur faces tha t a re to be f in ish-pa in ted a f te r ins ta l la t ion or requ i re cor ros ion pro tect ion unt i l
ins ta l la t ion , sha l l be shop pa in ted wi th a t least two coats o f p r imer . Transformers and o ther
electr ical equipments i f included shal l be shop f in ished with one or more coats of pr imer and
two coats of h igh grade resistance enamel. The f in ished colors shal l be as per manufacturer ’s
standards, to be selected and speci f ied by th e Em ployer at a lat er date.
Shop pr imer fo r a l l s tee l sur faces wh ich wi l l be exposed to opera t ing tempera ture be low 95degrees Celsius shal l be selected by the Contractor after obtain ing speci f ic approval of the
Employer regard ing the qua l i ty o f p r imer proposed to be app l ied . Specia l h igh tempera ture
pr imer shal l be used on surfaces exposed to temperature higher than 95 degrees Celsius and
such pr im er shal l a lso be sub ject to the appro va l o f t he Employer .
Al l ot her steel surfaces which are not t o be paint ed shal l be coated w ith sui table rust prevent ive
compou nd sub ject t o t he approva l o f the Emp loyer .
Al l p ip ing shal l be cleaned aft er shop assem bly.
Paint ing fo r Civi l stru ctu res shal l be do ne as per re levant part of technical speci f icat ion
4.11 QU ALITY ASSURAN CE PROGRAM M E
The Cont ractor shal l adopt sui table qual i ty assurance program m e to ensure that t he equipm ent
and serv ices under the scope o f contract whether manufactured or per fo rmed wi th in the
Cont ractor ’s wo rks or at h is sub -con tracto r ’s prem ises or at th e Em ployer ’s si te or at any oth er
place of w ork are in accordance w ith t he speci f icat ion s. Such pro gramm es shal l be out l ined by
the Contractor and shal l be f inal ly accepted by the Employer/author ised representat ive after
discussions before t he aw ard of t he cont ract. The QA pro gramm e shal l be general ly in l ine w ith
IS/ISO- 9001.A qual i ty assurance programme of the contractor shal l general ly cover thefo l lowing:
(a ) His organ isa t ion s t ructure fo r the m anagement and im p lementa t ion o f t he proposed qua li ty
assurance program m e
(b ) Qual i ty System M anual
(c ) Design Cont rol System
(d ) Docum entat ion and Data Cont rol System
(e ) Qual i f icat ion dat a for Cont ractor ’s key personnel.
Technical Specificati ons: Genera l Technical Requirem ents Page 15 of 29
(f ) The procedure for purchase of mater ia ls, parts, components and select ion of sub-
contractor ’s services including vendor analysis, source inspection, incoming raw-mater ia l
inspection , ver i f icat ion o f m ater ia ls purchased et c.(g ) System for shop m anufactu r ing and site er ect ion contr ols includ ing process, fabr icat ion and
assembly.
(h ) Contro l o f non-conforming i tems and system for cor rect ive act ions and reso lu t ion o f
deviat ions.
(i ) Inspect ion and test p rocedure bot h fo r m anufacture and f ie ld act ivi t ies.
(j ) Contro l o f cal ib rat ion and test ing o f m easur ing test ing equ ipm ent .
(k ) System fo r Qual i ty Audi ts.
(l ) System fo r ident i f icat ion and appraisal of inspection statu s.
(m ) System for au t hor is ing re lease o f manufactured p roduct t o the Em ployer .
(n ) System for handl ing, sto rage and del ivery.(o ) System fo r m aintenance of re cords, and
(p ) Qual i ty p lans for manufactur ing and f ie ld act iv i t ies detai l ing out the speci f ic qual i ty control
procedure adopted for control l ing the qual i ty character ist ics re levant to each i tem of
equ ipmen t /componen t .
4.12 GENERAL REQUI REM ENTS - Q UA LITY ASSURAN CE
4.12.1 Al l m ater ia ls, com pon ents and equipm ent covered under th is speci f icat ion shall be procur ed,
manufactured, erected, commissioned and tested at a l l the stages, as per a comprehensive
Qual i ty Assurance Program m e. An indicat ive program m e of inspection/ tests to be carr ied out b yth e contracto r for som e of th e major i t em s is g iven in the respective technical speci f icat ion . This
is , however , no t in tended to fo rm a comprehensive programme as i t i s the contractor ’s
responsib i l ity t o d raw up and imp lement such program m e du ly approved by t he Emp loyer . The
detai led Qual i ty Plans for m anufactu r ing and f ie ld act iv i t ies shall be draw n up b y the Contr actor
and w i l l be subm itted to Em ployer fo r appro val . Schedule of f inal isat ion of such qual i ty p lans wi l l
be f inal ised befo re aw ard. M ont hly progress repor ts on M QP/ FQP subm ission/ appro val shal l be
fur nished on en closed fo rmat No . QS-01-QAI-P-02/ F1.
4 .12.2 M anufactur ing Qua l ity P lan w i ll de ta i l ou t fo r a l l the compo nents and equ ipment , var ious
tests/ inspection, to be carr ied out as per the requirements of th is speci f icat ion and standardsment ioned there in and qua l i ty p ract ices and procedures fo l lowed by Contractor ’s / Sub-
cont ractor ’s/ sub-suppl ier 's Qual i ty Cont rol Organisat ion , the re levant reference docum ent s and
standards, acceptance norms, inspection documents ra ised etc., dur ing al l stages of mater ia ls
procurement, manufacture, assembly and f inal test ing/performance test ing. The Qual i ty Plan
shall be subm itted o n electron ic media e.g. f lopp y or E-mai l in addi t ion t o hard copy, for r eview
and approva l . A f te r appro va l the same sha l l be subm i t ted in compi led fo rm on CD-ROM .
4.12.3 Fie ld Qual i ty Plans w i ll detai l out for a l l th e equipm ent, the qual i ty pract ices and procedure s etc.
to be fo l lowed by the Contractor ’s "Si te Qual i ty Control Organisat ion", dur ing var ious stages of
s ite act iv i t ies sta r t ing f ro m rece ip t o f m ater ia ls /equ ipm ent a t si te .
Technical Specificati ons: Genera l Technical Requirem ents Page 16 of 29
4.12.4 The Cont ractor shal l a lso furn ish cop ies of th e reference do cumen ts/ plant standards/acceptance
no rm s/t ests and inspection pro cedure et c., as referred in Qual i ty Plans along w ith Qual i ty Plans.
These Qual i ty Plans and reference documents/standards etc. wi l l be subject to Employer ’sapprova l w i thou t w h ich manufacturer sha l l no t p roceed. These approved docum ents shal l fo rm
a part of the contract. In these approved Qual i ty Plans, Employer shal l identi fy customer hold
points (CHP), i .e. test/checks which shal l be carr ied out in presence of the Employer ’s Project
M anager or h is au thor ised representa t ive and beyond w h ich t he wo rk w i ll no t p roceed w i thout
consent of Employer in wr i t ing. Al l deviat ions to th is speci f icat ion, approved qual i ty p lans and
app l icab le s tandards must be documented and re fer red to Employer a long wi th techn ica l
ju st if icat io n fo r ap p roval an d d isp o sit io n in g.
4 .12.5 No m ater ia l sha l l be despatched f rom the m anufacturer ’s works before the same is accepted,
subsequent to predespatch f inal inspection including ver i f icat ion of records of a l l previoustests/ inspections by Emp loyer ’s Project M anager/Aut hor ised representat ive and duly author ised
for despatch by issuance o f M ater ia l Despatch Clearance Cert i f icate (M DCC).
4.12.6 Al l m ater ia l used for equipm ent m anufactu re including cast ing and forging etc. shal l be of tested
qual i ty as per re levant codes/standards. Detai ls of resul ts of the tests conducted to determine
the mechanical propert ies; chemical analysis and detai ls of heat treatment procedure
recommended and actua l ly fo l lowed sha l l be recorded on cer t i f i ca tes and t ime tempera ture
chart. Tests shal l be carr ied out as per appl icable m ater ia l standards and/ or agreed d etai ls.
4.12.7 The cont ractor shall subm it to the Em ployer Fie ld Welding Schedule for f ie ld w elding act iv i t ies inth e enclosed f orm at No .: QS-01-QAI-P-02/ F3. The f ie ld w elding schedule shal l be subm itted to
the Employer a long wi th a l l suppor t ing documents, l i ke we ld ing procedures, heat t rea tment
procedures, NDT procedures etc. at least n inety days before schedule star t of erect ion work at
site.
4.12.8 Al l w elding and brazing shal l be carr ied ou t as per procedu re draw n and qual i f ied in accordance
w ith r equirem ents of ASM E Section IX/ BS-4870 or oth er Internat ional equivalent standard
acceptable to the Employer. Al l w elding/ brazing procedures shal l be subm itted t o th e Emp loyer
or i ts au thor ized representa t ive fo r approva l p r io r to car ry ing out t he w e ld ing /b razing.
4.12.9 Al l brazers, w elders and w elding operat ors em ployed on any part of the cont ract e i ther in
Cont ractor ’s/sub-cont ractor ’s wo rks or at s ite o r e lsew here shall be qual i f ied as per ASM E
Section-IX or BS-4871 or o ther equivalent Int ernational Standard s accept able to the Emp loyer.
4.12.10 W elding procedure qu al if icat ion & W elder qual i f icat ion t est resul ts shal l be furnished to th e
Employer for approval . However, where required by the Employer, tests shal l be conducted in
presence of Employer/author ised representat ive.
4.12.11 Unless otherwise proven and speci f ical ly agreed with the Employer, welding of d issimi lar
m ater ia ls and high al loy m ater ia ls shall be carr ied out at shop o nly.
Technical Specificati ons: Genera l Technical Requirem ents Page 17 of 29
4.12.12No w elding shal l be carr ied out on cast i ron comp onent s for r epair .
4 .12 .13 A ll the h eat t rea tm ent r esu l ts sha l l be recorded on t im e tem pera ture char ts and ver i f ied w i threcom mended r eg im es.
4.12.14 Al l non-destruct ive examination shal l be performed in accordance with wr i t ten procedures as
per International Standards, The NDT operator shal l be qual i f ied as per SNT-TC-IA (of the
American Society of non-destruct ive examination). NDT shal l be recorded in a report, which
includes detai ls of methods and equipment used, resul t /evaluation, job data and identi f icat ion
of p ersonne l employed and deta i ls o f cor re la t ion o f th e test repor t w i th t he job . A l l Bar s tock /
for gings of d iamet er equal to or greater than 50m m shal l be ul tr asonical ly tested . In general a l l
p lates of th ickness equal to or greater than 40mm and for pressure parts, pates of th ickness
equal to or greater than 25mm shal l be ul trasonical ly tested unless as speci f ied otherwise inrespective equipm ent speci f icat ion.
4 .12.15The Contractor sha l l l i s t ou t a l l ma jor i tems/ equ ipment / components to be manufactured in
house as wel l as procured from sub-contractors. Al l the subcontractor proposed by the
Cont ractor for p rocurem ent o f major bou ght out i tem s including cast ings, forging, sem i-f in ished
and f in ished comp onents /equ ipm ent e tc . , li st o f w h ich sha ll be drawn up by the Contractor and
final ised w ith t he Em ployer, shal l be subject to Emp loyer 's approval . The cont ractor ’s propo sal
shal l include vendor ’s faci l i t ies establ ished at the respective works, the process capabi l i ty,
process stabi l izat ion, QC systems fo l lowed, exper ience l ist , etc. a long with h is own technical
eva lua t ion fo r ident i f ied sub-contractors enc losed and sha ll be subm i t ted to the Emp loyer fo rapproval wi th in the per iod agreed at the t ime of pre-awards discussion and identi f ied in "DR"
category pr io r to any procurement . M onth ly p rogress repor t s on sub-cont ractor de ta i l
subm ission / appro val shal l be furn ished. Such vendo r appr oval shal l not re l ieve the cont ractor
f rom any ob l iga t ion , du ty or responsib il ity un der th e contract .
4 .12 .16For comp onent s/ equ ipment p rocured by th e contractor s fo r t he purpose o f th e contract , a f te r
obtain ing the wr i t ten approval of the Employer, the contractor ’s purchase speci f icat ions and
inqu ir ies shal l call for q ual i ty p lans to be subm itted by t he suppl iers. The qual i ty p lans cal led fo r
fro m t he sub -cont ractor shal l set ou t, dur ing th e var ious stages of m anufactur e and instal lat ion,
the qual i ty pract ices and procedures fo l lowed by the vendor ’s qual i ty control organisat ion, the
relevant reference documents/standards used, acceptance level , inspection of documentat ion
raised, etc. Such qua l i ty p lans of th e successful vendors shall be f inal ised w ith th e Em ployer and
such approved Qua l i ty P lans sha l l fo rm a par t o f the purchase order /contract be tween the
Contractor and sub-contractor . Wi th in th ree weeks o f the re lease o f the purchase orders
/ co n t rac t s f o r such b ough t ou t it em s / co m p onen ts, a co py o f t h e sam e w it h ou t p r ice det ai ls bu t
to gether w i th t he det ai led purchase speci f icat ion s, qual i ty p lans and del ivery condi t io ns shal l be
furn ished to the Employer on the month ly bas is by the Contractor a long wi th a repor t o f the
Purchase Order p laced so far for th e cont ract. **
Technical Specificati ons: Genera l Technical Requirem ents Page 19 of 29
(c ) M anufacturer / w orks test repor ts / resu l ts fo r t est ing requ i red as per app l icab le codes and
standard referred in th e speci f icat ion and approved Qual i ty Plans.
(d ) Non-destruct ive examination resul ts /reports including radiography interpretat ion reports.Sketches/ drawings used fo r ind ica t ing the m ethod o f t raceab i li ty o f the rad iographs to th e
locat ion on the equ ipm ent .
(e ) Heat Treatm ent Cert i f icate/ Record (Tim e- tem peratu re Chart )
(f ) Al l the accepted No n-conform ance Repor ts (Major / M inor ) / dev ia t ion , inc lud ing com ple te
techn ical detai ls / repair pro cedure).
(g ) Inspection reports duly signed by the Inspector of the Employer and Contractor for the
agreed Custom er Hold Points.
(h ) Cert i f icate o f Conform ance (COC) w herever ap pl icable.
(i ) M DCC
4.13.3 Simi la r ly , the contractor sha l l be requ i red to subm i t tw o se ts ( tw o hard cop ies and tw o CD
ROM s), cont ain ing QA Docum ent at ion p erta in ing to f ie ld act iv i t ies as per Appro ved Field Qual i ty
Plans and ot her agreed manuals/ p rocedures, pr ior to com m issioning of ind ividual system .
4.13.4 Before despatch / com m issioning of any equipm ent , th e Supp l ier shal l m ake sure that t he
corresponding qual i ty document or in the case of protracted phased del iver ies, the appl icable
section of the qual i ty document f i le is completed. The suppl ier wi l l then noti fy the Inspector
regarding the readiness of the qual i ty document (or appl icable sect ion) for review. I f the resul t
of the review carr ied out by the Inspector is sat isfactory, the Inspector shal l stamp the qual i ty
document (or appl icable sect ion) for re lease. I f the qual i ty document is unsatisfactory, theSuppl ier shal l endeavor to correct the incompleteness, thus al lowing to f inal ize the qual i ty
document (o r app l icab le sect ion) by t ime compat ib le wi th the requ i rements as per contract
documents. When i t i s done, the qua l i ty document (o r app l icab le sect ion) is s tamped by the
Inspector. I f a decision is made despatch, whereas al l outstanding act ions cannot be readi ly
c leared fo r the r e lease o f the q ua l ity docum ent by tha t t ime. The supp l ie r shal l im m edia te ly ,
upon sh ipment o f the equ ipm ent , send a copy o f t he qua l ity do cument Review Sta tus signed by
the Supp l ie r Representa t ive to the Inspector and not i fy o f the commi t ted date fo r the
complet ion of a l l outstanding act ions & submission. The Inspector shal l stamp the qual i ty
document for appl icable sect ion when i t is effect ively completed. The submission of QA
docum enta t ion package sha l l no t be la te r t han 3 w eeks a f te r the despatch o f equ ipment .
4.13 .5 TRANSM ISSION O F QA DOCUM ENTATION
On re lease o f QA Documenta t ion by Inspector , one set o f qua l i ty docum ent sha ll be fo r warded
to Corporate Qual i ty Assurance Department and other set to respective Project Si te of
Employer. For the part icular case of phased del iver ies, the complete qual i ty document to the
Emp loyer sha l l be issued not la te r than 3 w eeks a f te r the date o f the last de l ivery o f equ ipment .
Technical Specificati ons: Genera l Technical Requirem ents Page 20 of 29
4.14.1 To el iminate delays and avoid disputes and l i t igat ion, i t is agreed between the part ies to the
Cont ract t ha t a l l mat t e rs and quest ions sha l l be re fer red to the Pro ject M anager and w i thout
prejud ice to th e provision s of ‘Arbi trat ion’ c lause in GCC, the Con tractor shal l proceed t o com plyw i th the Pro ject M anager 's dec ision .
4 .14.2 The w ork sha l l be per fo rm ed under the superv ision o f t he Pro ject M anager . The scope o f the
dut ies o f the Pro ject M anager pursuant t o th e Cont ract , w i l l inc lude but no t b e l im i ted t o th e
fo l lowing:
(a ) In te rp re ta t ion o f a l l the te rm s and cond i t ions o f t hese do cuments and spec if icat ions:
(b ) Review and int erpret at ion o f a l l th e Cont ractor ’s drawin g, engineer ing data, etc:
(c ) Witness or h is author ised representat ive to wi tness tests and tr ia ls e i ther at the
manufacturer ’s works or a t s i te , o r a t any p lace where work is per fo rmed under the
contract :(d ) Inspect , accept o r re ject any equ ipment , mater ia l and w ork under the cont ract :
(e ) Issue cert i f icate o f acceptance and/ or pr ogressive payment and f inal paym ent cert i f icates
(f ) Review and suggest mo d i f ica t ions and improvem ent in comple t ion schedu les f rom t ime to
t ime, and
(g ) Super vise Qual i ty Assurance Programm e imp lement at ion at a l l stages of t he w orks.
4.15 IN SPECTION , T ESTING AN D IN SPECTION CERTIFICATES
(a ) The wor d ‘ Inspector ’ shal l m ean the Project M anager and/ or h is aut hor ized representat ive
and/or an outside inspection agency act ing on behal f of the Employer to inspect and examinethe m ater ia ls and w orkm ansh ip o f t he w orks dur ing i ts manufactur e or e rect ion .
(b ) The Project M anager or h is du ly autho r ised representat ive and/ or an ou tside inspection agency
acting on behal f of the Employer shal l have access at a l l reasonable t imes to inspect and
exam ine the m ater ia ls and w orkm ansh ip o f the wo rks dur ing i ts manufacture or e rect ion and i f
par t o f the works is be ing manufactured or assembled on o ther p remises or works, the
Contractor shal l obtain for the Project Manager and for h is duly author ised representat ive
perm ission to inspect as if t he w orks were m anufactured o r assemb led o n th e Contr actor ’s ow n
prem ises or w orks.
(c) The Contractor shal l g ive the Project Manager/Inspector f i f teen (15) days wr i t ten notice of any
mater ia l being ready for test ing. Such tests shal l be to the Contractor ’s account except for the
expenses of th e Inspecto r ’s. The Project M anager/Inspector, unless th e wit nessing of the t ests is
v i r tua l ly w a ived and conf i rm ed in w r i t ing , w i ll a t tend such t ests wi th in f i f teen (15) days o f t he
date on wh ich the equ ipment is no t iced as be ing ready fo r test / inspect ion fa i l ing wh ich the
contractor may p roceed w i th test w h ich sha ll be deemed to h ave been m ade in the inspector ’s
presence and he shal l for thwith forward to the inspector duly cert i f ied copies of test reports in
tw o (2) cop ies.
(d ) The Project Manager or Inspector shal l wi th in f i f teen (15) days from the date of inspection asdef ined here in g ive not ice in w r i t ing to the Contractor , o r any ob ject ion to any draw ings and a l l
Technical Specificati ons: Genera l Technical Requirem ents Page 21 of 29
or any equ ipm ent and w orkmansh ip wh ich is in h is op in ion not in accordance wi th the cont ract .
The Contractor shal l g ive due considerat ion to such object ions and shal l e i ther make
m odi f ica t ions tha t m ay be necessary to meet the sa id ob ject ions or sha l l in fo rm in w r i t ing to t heProject M anager/ Inspecto r g iving reasons therein , that n o m od if icat ions are necessary t o
comply wi th th e contract .
(e ) W hen t he factory tests have been comp le ted a t th e Contr actor ’s o r sub-contractor ’s wo rks, the
Project M anager / Inspector shal l issue a cert i f icate to th is effect f i f teen (15) days aft er
comple t ion o f t ests bu t i f the t ests are not w i tnessed by th e Pro ject M anager / Inspectors , the
cert i f icate shal l be issued with in f i f teen (15) days of the receipt of the Contractor ’s test
cert i f icate by th e Project M anager / Inspector. Project M anager / Inspecto r to issue such a
cer t i f ica te sha l l no t p revent th e Contr actor f rom proceed ing w i th t he w orks. The com ple t ion o f
these tests or the issue of the cert i f icates shal l not b ind the Employer to accept the equipment
shou ld i t , on fu r t her tests a f te r e rect ion be found n ot t o comp ly wi th th e contract .
(f ) In a l l cases where the contract p rov ides fo r tests whether a t the premises or works o f the
Contractor or any sub-contractor, the Contractor, except where otherwise speci f ied shal l
pro vide free o f charge such i tem s as labour , m ater ia l , e lectr ic ity, fu el , w ater, stores, apparatu s
and instruments as may be reasonably demanded by the Project Manager / Inspector or h is
author ised representat ives to carry out effect ively such tests on the equipment in accordance
w i th t he Contr actor and shal l g ive fac i li t ies to the Pro ject M anager / Inspector o r t o h is
auth or ised repre sentat ive to accom pl ish test ing.
(g) The inspection b y Project M anager / Inspecto r and issue of Inspection Cert i f icate th ereon shallin no way l imit the l iabi l i t ies and responsibi l i t ies of the Contractor in respect of the agreed
Qual ity Assurance Programm e form ing a par t o f the contract .
(h ) To faci l i tate advance planning of inspection, the Contractor shal l furnish quarter ly inspection
pro gramm e indicat ing schedule dates of inspection at Custom er Hold Point and f inal inspection
stages. Updat ed quart er ly inspection p lans w i l l be m ade for each thr ee consecut ive mon ths and
shall be furn ished befo re beginning of each calendar m ont h.
(i ) All inspection, m easur ing and t est equ ipm ent u sed b y cont ractor shal l be cal ibrat ed per iod ical ly
depend ing on i ts use and cr i t i cal ity o f t he t est / m easurem ent to be don e. The Cont ractor sha l l
maintain al l the re levant records of per iodic cal ibrat ion and instrument identi f icat ion, and shal l
prod uce th e sam e for in spection b y NALCO. W herever asked speci f ical ly, the con tracto r shall re-
ca lib ra te the m easur ing / test equ ipm ent in the presence o f Pro ject M anager / Inspector .
4.16 PRE-COM M ISSIONING AND COM M ISSIONING FACILITIES
(a ) As soon as the faci l it ies or part the reof has been comp leted op erat ional ly and structur al ly
and before star t -up , each i tem o f the equ ipment and system s fo rming par t o f faci l it ies sha l l
be t horough ly c leaned and then inspected jo in t ly by t he Employer and th e Contractor f o r
correctness of and completeness of faci l i ty or part thereof and acceptabi l i ty for in i t ia l pre-
Technical Specificati ons: Genera l Technical Requirem ents Page 22 of 29
commissioning tests, commissioning and star t-up at Si te. The l ist of pre-commissioning
tests to be performed shal l be as mutual ly agreed and included in the Contractor ’s qual i ty
assurance pr ogramm e as wel l as th ose included elsew here in t he Technical Speci f icat ion s.
(b ) The Contractor ’s pre-commissioning/ commissioning/star t-up engineers, special ly
identi f ied as far as possib le, shal l be responsible for carrying out a l l the p re-com m issioning
tests at Si te. On complet ion of inspection, checking and after the pre-commissioning tests
are sat isfactor i ly over, the commissioning of the complete faci l i t ies shal l be commenced
dur ing wh ich per iod the comple te fac i l i t ies , equ ipments sha l l be opera ted in tegra l w i th
sub-system s and support ing equipm ent as a comp lete plant.
(c ) The t im e consumed in the inspection and checking of the un i ts shal l be considered as a part
o f t he erect ion and insta lla t ion per iod .
(d ) The check outs dur ing the pre - comm ission ing per iod shou ld be programm ed to fo l low the
construct ion complet ion schedule. Each equipment/system, as i t is completed in
construct ion and tu rned o ver to Emp loyer 's com m issioning (star t up) Engineer(s) , shou ld be
checked out and cleaned. The checking and inspection of individual systems should then
fol low a p rescr ibed com m issioning do cum entat ion [SLs (Standa rd Check List) / TS (Testing
Schedule) / CS (Com m issioning Schedule)] app roved by th e Employer.
(e ) On com plet ion o f a l l pre-com m issioning act iv i t ies / tests and as a part of com m issioning th e
complete faci l i t ies shal l be put on 'Tr ia l Operat ion' dur ing which per iod al l necessaryadjustm ents shal l be made w hi le operat ing over t he fu l l load range enabl ing th e faci li t ies to
be m ade ready for th e Guarant ee Tests
(f ) The durat ion of 'Tr ia l Operat ion' of the complete faci l i ty as an integral uni t shal l be
fou rteen (14) days. The Tr ia l Operat ion shal l be considered successful , pro vided t hat each
i tem / part o f th e facil i ty can operate cont inuously at the specif ied operat in g character ist ics,
fo r the per iod o f Tr ia l Opera t ion w i th a l l opera t ing parameters wi th in th e spec if ied l im i ts
and a t o r near the pred icted per fo rm ance o f fac i li ty / equ ipm ent .
(g ) For the p er iod o f 'Tr ia l Operat ion ' , the t ime o f opera t ion w i th any load sha l l be counted.
M inor in t e r rup t ions not exceed ing four (4 ) hours at a t ime caused du r ing the 14 days t r ia l
opera t ion per iod sha ll no t e f fect th e to t a l dura t ion o f In i t ia l Operat ion . I f in th e op in ion o f
th e Em ployer th e int errup tion is long, the Tr ia l Operat ion shal l be prolonged fo r the per iod
of in te r rup t ion
(h ) A Tr ia l Operat ion report comprising of observations and recordings of var ious parameters
to be m easured in respect o f th e above Tr ia l Opera t ion sha l l be p repared by the Contractor .
This report , besides recording the d etai ls of t he var ious observations dur ing tr ia l op erat ion
shal l a lso include the dat es of star t and f in ish o f t he Tr ia l Operat ion and shal l be signed by
the representat ives of both the part ies. The report shal l have sheets, recording al l the
Technical Specificati ons: Genera l Technical Requirem ents Page 23 of 29
deta i ls o f in te r rup t ions occur red, ad justm ents made and any m inor repa i rs done d ur ing the
Tr ia l Operat ion. Based on the observations, necessary modif icat ions/repairs to the plant
sha l l be car r ied out by t he Contractor to the fu l l sa t isfact ion o f t he Pro ject M anager toenable the latter to accord permission to carry out the Guarantee tests on the faci l i t ies.
However , minor d e fects wh ich do no t endanger the safe opera t ion o f t he equ ipm ent , sha l l
not be considered as reasons for w i th- ho ld ing the aforesaid p erm ission
(i ) Contractor shal l furnish the commissioning organizat ion chart for review & acceptance of
employer at least e ighteen months pr ior to the schedule date of synchronizat ion of 1st
uni t . The chart shou ld cont ain:
a) Exper ience o f th e Comm issioning Engineers.
b ) Role and r espon sibi l i t ies of t he Com m issioning Organisat ion m emb ers.
c) Expected du rat ion of p ost ing of t he above Com m issioning Engineers at si te.
4.17 GUA RANTEE TESTS
(a ) The f inal tests as to the guarantees shal l be conducted at Si te, by the Contractor. The
Cont ractor 's Com m issioning and star t -up Engineers shal l make t he un i t ready for such te sts.
Such test w i l l be commenced, wi th in a per iod o f th ree (3) months a f te r the successfu l
comple t ion o f Tr ia l Opera t ion . Any extens ion o f t im e beyond t he above th r ee mon ths sha l l
be subject to Emplo yer 's appro val .
(b ) These tests sha l l be b ind ing on bo th the p ar t ies o f t he Contract t o d e termine com pl iance o fthe equ ipm ent w i th the per fo rm ance guarantee.
(c ) Any special equipment, tools and tackles required for the successful complet ion of the
Guarantee Tests shal l be provided b y th e Cont ractor, free of cost.
(d ) The guarantee f igures and des ign /per fo rmance parameters o f the equ ipment sha l l be
proved by the Contractor dur ing these Guarantee Tests / and o r du r ing t he 'Tr ia l opera t ion '
as detai led out e lsewhere. Should the resul ts of these tests show any deter iorat ion from
the guaranteed values, the Contractor shal l modify the equipment as required to enable i t
to m eet t he guarantees. In such case, the Guarant ee Tests shall be rep eated and al l cost form odif icat ions including labour, mat er ia ls and th e cost of addi t ional test ing to pro ve that th e
equ ipment m eets the guarantees, sha l l be borne b y the Contractor .
(e ) The speci f ic tests to be conducted on equ ipment have been brought ou t in the t echn ical
speci f icat ion.
4.18 Test Code s
The prov isions out l ined in the ASME Perform ance Test Codes shal l be used as a guide f or a l l th e
above t est procedur es unless ot herw ise specif ied in the t echnical specif icat ions.
Technical Specificati ons: Genera l Technical Requirem ents Page 25 of 29
1. W orking platfo rm s shou ld be fenced and shal l have means of access.
2 . Ladders in accordance with Employer ’s safety ru les for construct ion and erect ion shal l be
used. Rungs shal l not b e w elded on column s. Al l th e sta irs shall be pro vided w ith handrai lsimm edia te ly a f te r i ts e rect ion .
4.22 NO ISE LEVEL
The equivalent 'A ' weighted sound pressure level measured at a height of 1.5 m above f loor
level in e levation and at a d istance of on e (1) m etre ho r izon tal ly from the n earest surface of any
equipm ent / m achine, furn ished and in stalled und er th ese speci f icat ion s, expressed in decibels
to a reference of 0.0002 m icrobar, shal l not exceed 85 dBA.
4.23 PACKAGING AND TRANSPORTATION
All the equipments shal l be sui tably protected, coated, covered or boxed and crated to prevent
damage or deter iorat ion dur ing transi t , handl ing and storage at Si te t i l l the t ime of erect ion.
Whi le packing al l the mater ia ls, the l imi tat ion from the point of v iew of the sizes of ra i lway
wagons avai lable in India should be taken account of. The Contractor shal l be responsible for
any loss or damage dur ing transportat ion, handl ing and storage due to improper packing. The
Cont ractor shal l ascerta in t he avai labi l i ty o f Rai lway w agon sizes from th e Indian Rai lways or any
other agency concerned in India wel l before effect ing despatch of equipment. Before despatch
i t shal l be ensured that complete processing and manufactur ing of the components is carr ied
out a t shop, on ly rest r ic ted by t ranspor t l im i ta t ion , in o rder to ensure tha t s i te works l i ke
gr inding, welding, cut t ing & pre-assem bly to bare m inimum . The Em ployer 's Inspecto r shal l have
r igh t to insist f o r comple t ion o f w orks in shops before despatch o f m ater ia ls fo r t ranspor ta t ion .
4. 24 ELECTRICAL ENCLO SURE
All e lectr ical equipm ents and devices, including insulat ion , heating and venti lat ion devices shal l
be des igned fo r am bient tem pera ture (500C) and a maximum re la t ive hum id ity (75%).
4.25 INSTRUM ENTATION AND CONTROL
Al l ins t rumenta t ion and contro l systems/ equ ipment / dev ices/ components , fu rn ished underth is contract shal l be in accordance with the requirements stated herein, unless otherwise
specif ied in th e det ai led speci f icat ion s.
Al l instrument scales and charts shal l be cal ibrated and pr inted in metr ic uni ts and shal l have
l inear graduation. The ranges shal l be selected t o have t he no rm al reading at 75% of fu l l scale.
Al l scales and chart s shal l be cal ibrat ed and p r int ed in M etr ic Uni ts as fo l low s:
a) Tempe rature - Degree cent igrade (deg C)
b ) Pressure - Ki lograms per square centimetre (Kg/cm2). Pressure instrument shal l have
th e uni t suff ixed w ith 'a ' to indicate absolut e pressure. If not hing is the re, that w i l l m eanthat th e indicated p ressure is gauge pressure.
Technical Specificati ons: Genera l Technical Requirem ents Page 26 of 29
c) Draught - M i l limetr es o f w ater co lum n (mm w c).
d ) Vacuum - M i l limeters o f mercury co lum n (mm Hg) or water co lumn (mm W cl) .
e) Flow - Tonnes/ hou rf ) Flow (Liquid) - Tonn es / ho ur
g) Flow base - 760 mm Hg. 15 deg.C
h ) Density Grams per cubic centim etr e.
Al l instru m ents and cont rol devices pro vided on p anels shal l be of m iniatur ized design, sui tab le
for m odu lar f lush m ount ing on pane ls w i th f ron t d raw out faci l ity and f lexib le p lug- in connect ion
at rear .
Al l e lectronic modules shal l have gold plated connector f ingers and fur ther a l l input and output
m odu les shal l be short c i rcui t proo f. These shal l a lso be t ropical ised & com pon ents shall be ofindustr ia l g rade or be t te r .
4.2 6 ELECTRICAL N O ISE CON TROL
The equip m ent fu rnished by the Cont ractor shal l incorporat e necessary techniques to el im inate
m easure m ent and con tro l problem s caused by electr ical noise. Areas in Cont ractor 's equipm ent
which are vulnerable to e lectr ical noise shal l be hardened to el iminate possible problems. Any
addit ional equipment, services required for effect ively e l iminating the noise problems shal l be
includ ed in t he p rop osal. The equip m ent shall be pro tect ed against ESD as per IEC-801- 2. Radio
Frequency inter ference (RFI) and Electro M agnetic Inter f erence (EM I) prot ect ion againsthardw are damage and cont rol system mal-operat ions/erro rs shal l be pro vided for a l l system s.
4.27 TAPPING POINTS FOR M EASUREM ENTS
Tapping points shal l include probes, wherever appl icable, for analyt ical measurements and
sampl ing . For d i rect tempera ture measurement o f a l l work ing media , one s tub wi th in te rna l
threading of approved pattern shal l be provided along with sui table plug and washer. The
Contractor wi l l be in t imated about th read s tandard to be adopted. The fo l lowing sha l l be
prov ided on equ ipment by the Contractor . The s tandard wh ich is to be adopted wi l l be
in t imat ed to the Contractor . Temp era ture test po ckets wi th stub and th ermo w el l Pressure test
pockets
4.28 ELECTRONIC M OD ULE/ COM PONENT DETAILS
The Cont ractor shal l have t o furn ish al l t echnical detai ls including circui t d iagram s, speci f icat ions
of compon ents, e tc ., in respect o f each and every e lect ron ic card / mo du le as emp loyed o n t he
var ious sol id state as wel l as microprocessor based systems and equipment including
convent iona l ins t rum ents, per iphera ls e tc . It i s mandatory fo r the Contractor t o ident i fy c lear ly
the custom bui l t ICs used in the package. The Contractor shal l a lso furnish the detai ls of any
Technical Specificati ons: Genera l Technical Requirem ents Page 27 of 29
4.29 JU NCTION BOXES
The junct ion boxes shal l be made of minimum 2 mm thick sheet steel . Gland plates shal l beremovable type and made of 3 mm thick sheet steel . The boxes shal l be provided with
detachable cover or h inged doo r w i th capt ive screw s. Top o f th e box shal l be arranged to slope
towards the rear of the box. The box shal l be hot d ip galvanized and shal l be provided with
sui table neoprene gaskets to achieve degree of protect ion of IP-55 as per IS: 2147. Adequate
spacing shal l be provided to terminate the external cables. The boxes shal l be sui table for
mounting on var ious types of steel structures. The terminal b locks provided shal l be of 650 V
grade, rated fo r 10 A for con tro l cables. Sui tab le numb ering for t erm inal b locks shal l be done. In
case o f junct ion box fo r power cab le , the box sha l l be ra ted fo r maximum cur rent car ry ing
capacity. Term inal blo cks shall be of o ne p iece, kl ippon RSF-1 or ELM EX CSLT-1 t ype w ith
insulat ing barr iers.
4.30 INCOM ING POW ER SUPPLY TO W AGON TIPPLER
In coming power supp ly to Wagon t ipp le r , apron feeder , crusher & conveyor system wi l l be
taken from 33KV substat ion located near the 220KV switch yard. Laying Power
cab le /Transmiss ion l ine f rom the substa t ion to wagon t ipp le r a rea a long wi th prov is ion o f
t ransformer , sw i tch gear system & p ane ls w i ll be the scope o f the tenderer . Approx imate
d is tance f rom the substa t ion to the wagon t ipp le r a rea wi l l be 2 .00 Km. However , actua l
distance & Sui table rou te fo r laying of cable wi l l be assessed by th e party in consul tat ion w ith
Technical Specificati on: Electr ical Page 1 of 77
SECTIO N 6
ELECTRICS FOR ADDITIONAL COAL STORAGE AND HANDLING SYSTEM
1.0 SPECIAL IN STRUCTION S TO BIDD ERS
1.1 Inspection o f site by Bidder
Bidder shal l inspect the si te and examine and obtain al l information required and satisfy
himself regarding al l matters such as access to si te, communication, transport, r ight of way,
the avai labi l i ty of local labour, avai labi l i ty and rates of mater ia ls, local working condi t ions,
ext reme weather cond i t ions, uncer ta in ty o f weather , obstruct ions and h indrances tha t may
ar ise , e tc , w h ich may a f fect t he w ork o r cost thereof , be fore t he submission o f h is tender .
Ignorance of si te condi t ions shal l not be accepted as basis for any cla im for co mp ensation. The
submission of tender by Bidder wi l l be construed as evidence that such an examination was
made and any later cla ims / d isputes in regard to pr ice quoted shal l not be enterta ined or
considered.
Bidder shal l a lso indicate in h is b id al l the major assumptions including major design
assum pt ions / c r i te r ia made by h im on wh ich t he b id is based.
1.2 Com pliance w ith Specificat ion
All equipm ent and accessor ies covered under t h is speci f icat ion shal l conform to the “ Technical
Speci f icat ions” g iven in t h is docum ent.
In case altern ative type o f equipm ent is off ered, a ll technical part iculars of equ ipm ent o ffered ,
number of such equipment suppl ied in India, reference l ist of instal lat ions where such
equipment is in operat ion as per qual i fy ing requirements, type test cert i f icates of their
co l labora tors, type t est cer t i f i cates o f ind igenously m ade equ ipment , exten t o f im por t content
and avai labi l i ty of spares indigenously, a long with any other data for consider ing theal ternat ive equipm ent shal l be furn ished w ith t he offer . The Purchaser, ho w ever, reserves the
r ight t o accept o r re ject th e propo sal wi th out assigning any reason .
Al l equipment shal l be sui table for vol tage/frequency var iat ions and other data given in
Electr ical System Design.
The contractor shal l be responsible for sat isfactory working of system with guaranteed
parameters. Al l the major equipment shal l be instal led, tested and commissioned under
superv is ion o f representa t ive o f manufacturer o f respect ive equ ipm ent .
Technical Specificati on: Electr ical Page 4 of 77
insta l lat ion wo rk o f the t ype and m agn i tude covered in th is docum ent , in the sta te o f O r issa . The
contractor sha ll a lso b e requ i red t o o b ta in labour l i cense f ro m Sta tu t ory Aut hor i ty .
Copy o f th e l icense shal l be m ade available to t he Purchaser/ consul tant fo r ver i f icat ions dur ing
the execut ion o f contract .
Al l l inem en, w iremen, e lectr ic ians, supervisors and engineers engaged b y th e Bidder or h is sub-
Bidder shal l possess necessary val id l icense issued b y t he statu tor y aut hor i t y and the same shal l
be submi t t ed fo r ver i f ica t ion , if ca l led fo r .
1.8 Com pliance with rules, regulat ions, and obtaining statu tory app roval
All equipment/mater ia ls shal l be instal led in accordance with the requirements of re levant
standa rds, Ind ian electr ic i ty Rules, Indian Electr ic i ty Act, 2 003 and also the Factory Act. I t is t he
responsibi l i ty of the Bidder to see that the electr ical instal lat ion suppl ied and erected by him
shal l be t o the ent i re sat isfact ion of Chief Electr ical Inspector, Cent ral Electr ic ity Auth or i ty or any
other sta tu t ory bod y hav ing ju r isd ic t ion in t he area and a lso to the Purchaser / consu l tan t .
The responsibi li ty fo r ob tain ing al l stat ut ory approvals for th e instal lat ion to be carr ied ou t rests
ent i re ly wi th the contractor . I t sha l l be the responsib i l i ty o f the contractor to p repare and
submit a l l necessary drawings, calculat ions, test cert i f icates and relevant detai ls (other than
those given by the Purchaser/consul tant) to the Electr ical Inspector and obtain pr ior approval
fo r com mencing the w ork and fo r the comp le te insta lla t ion w ork done. The inspect ion fee fo r
statutory approvals shal l be re imbursed by the Purchaser on submission of documentary
evidence.
2.0 SCOPE AN D BRIEF DESCRIPTIO N OF W ORK AN D ELECTRICAL SYSTEM DESIGN CRITERIA
2.1 Genera l
The scope of work includes the basic engineer ing, detai led engineer ing, manufacture or
procurement of e lectr ical equipment, shop test ing, packing, transportat ion, loading, del ivery at
si te, un loading, sto rage at si te, handl ing, erect ion , pre-com m issioning t ests and com m issioning
of a l l equipm ent / system including prel im inary acceptance test, perform ance guarant ee and po st
commissioning services, including insurance cover dur ing transi t , storage, erect ion andcom m ission ing. After successful com m issioning, the comm issioning spares not used, wi l l be the
property of the Purchaser. The job shal l be done on turnkey basis. Scope of Bidder shal l a lso
inc lude t he fo l low ing:
• Supp ly of comm issioning spares
• Supply o f mandatory spares requ i red fo r t w o years norm al O&M
• Supp ly of special too ls and t ackles for th e equipm ent/ system s supp l ied
2.2 Bidder shal l provide complete design inputs in form of assignment indicat ing completerequ iremen ts of civ il bui ld ing to accom mo date com fort ably an electr ical substat ion con sist ing of
Technical Specificati on: Electr ical Page 5 of 77
electr ical equ ipm ent u nder h is scope as wel l as the equipm ent u nder scope of t he Purchaser (as
indicated later on in th is speci f icat ion) meeting al l the required statutory clearances. The
bui ld ing shal l be f inal ized and constru cted by t he bidder
Bidder shal l a lso p rovide t he fo l low ing design input s for det ai led design and engineer ing of civ i l
and structural works i .e. foundations, room, etc. The same shal l be taken into considerat ionw hi le designing t he civi l bui ld ings by purchaser:
• Stat ic and dynamic load ing o f the equ ipm ent
• Clearances, app roach, safety exit s requ ired
Clearances from al l th e fou r sides of th e wal ls shall be m aintained, w herever appl icable in t he
electr ical premises w hi le g iving t he d esign input s.
The civi l bui ld ings for the complete WTP substat ion ( including switchgear room, battery room,
tran sfor m er room s, etc) , dust suppression M CC room , electr ic room for W TP, Apron feed er,Sizer etc shall be u nder t he scope o f Purchaser. Electr ical sub-stat ion w i l l be instal led in t he ou t
door n ear th e wagon t ipp le r sta t ion .
2.3 Bidder shall also take int o con sid erat ion of variou s aspects l ike clearances, appr oach , safet y
exists, cable trenches, foundations, f loor opening, inserts, underground GI p ipes, off ice
prem ises, etc w hi le f inal izing the d esigning of civ i l instal lat ion s and bu i ld ing w ith in bat ter y l imi t
of t he package.
2.4 For HT dr ives l ike sizer scope of the Bidder star ts from out going term inals of 6.6 kV switchboard
( to be insta l led a t the sw i tchgear room ) and inc ludes com ple te e lect r ics dow n be low up t o andincluding the dr ives / mechanism including power and control cabl ing (standard power and
cont rol cables shal l be issued free of cost to the Successful Bidder) , mo to rs, local push bu tt on
stat ions, equip m ent earth ing, etc.
For WT System Bidder shal l include complete electr ics including al l the equipment/services on
tu rnkey basis as per requirem ent i r respective of t he sam e is speci f ied in th e speci f icat ion or no t.
Separate set of sui table rat ed 6.6/ 0.433 kV transform ers, dedicated M CC for W T System
m achine, PLC, UPS w ith sealed m aintenance free batt er ies, VVVF dr ive con tro l system , junct ion
boxes, o ther equ ipm ent , e tc sha l l be inc luded fo r smoot h opera t ion o f w agon t ipp le r system .
A i r cond i t ion ing o f contro l room to be done wi th prov is ion o f sp l i t a i r cond i t ion o f su i tab le
capaci ty. For o ther LT dr ives and m echanism , Bidder shal l include d edicated M CCs consist ing o f
requ i red num ber and capacity o f o u tgo ing feeders.
For dry fog type dust suppression systems of transfer points in junct ion houses, Bidder shal l
inc lude a ded ica ted M CC in pu mp cum compressor hou se.
For miscel laneous and non-cr i t ical loads l ike power socket cabinets, venti lat ion, AC power
requ iremen t o f 6.6 kV sw itchboard / 4 15V PCC / tran sform er marshal l ing boxes, etc, Bidder shal l
Technical Specificati on: Electr ical Page 6 of 77
For i l lum ination o f W T System (W agon Tippler , Apron feed er, Sizer) including conveyor s and
substat ion, dust suppression room and adjoin ing areas / sub areas, Bidder shal l consider a
dedicated LDB and suff ic ient num ber of SLDBs. SLDB shal l be t imer cont rol . Two num bers f lood
l igh t h igh mast to w ers sha l l be inc luded fo r i l lum inat ion o f WT Area w i th met a l H lide Lamp s.
I l lum ination o f street l ight and conveyor gallery shal l be with LED lamp s.A separate room shal l be provided adjacent to WT control room to house the Dust suppression
M CC, Pum ps, comp ressors etc f or t he DS System by t he Bidder. Bidder shal l furn ish the
com plete re quirem ent s including size, cable trenches/o pening, etc. The p ressur ized venti lat ion
shal l be pro vided by th e Bidder in th is Dust Supp ression Room .
For DC power/control supply, Bidder ’s scope shal l star t from DCDB to be instal led at WT
substa t ion by th e b idder .
The number of MCCs / DBs shal l be provided as per requirement and i t wi l l be subject to
approval of Purchaser / h is consul tant .
Fol low ing shal l a lso b e included in th e Bidder ’s scope:
• Pressur ized venti lat ion system fo r th e sw itchgear cum M CC roo m
• Pressur ized vent i lat ion system for th e Dust Supp ression M CC room
• Air -cond i t ion ing o f ba t te ry and bat te ry charger room
• Exhaust fan in th e t ransform er room s.
The bidder shal l supply the PLC for safe operat ion of WT System. Necessary integrat ion with
exist in g PLC of n ew coal yard w i l l be scope o f t ender. Design and instal lat ion of e lectr ics shal l
ensure op era t ion o f comple te in tegra ted e lect r ics o f th e var ious dr ives/ m echan ism w i thout any
constra in t dur ing m ain tenance.
Bidder shall a lso con sider suff ic ient num bers of local auxil iary PDBs to cater m iscel laneous loads
of WT System. These PDBs shall be located at various places and exact locations shall be
f inal ized du r ing deta i led engineer ing.
HT Power cables and LT power/control cables shal l be la id in d i f ferent cable trays. LT power
cables and LT contr ol cables shal l a lso b e la id in d i f feren t trays, how ever, i f n ecessity ar ises due
to space constraints or lesser num ber of cables, LT pow er cables and LT cont rol cables can b e
put on t he same tr ays keeping suff ic ient gap bet w een th em . 24V DC cables, if requ ired, shal l be
la id ent i re ly in d i f fer ent ded icated t rays.
Cable trays in single t ier o r in m ult i t ier shal l be instal led in vert ical arrangement everyw here t o
avert coal accum ulat ion and space reduction. Cable trays shal l be suppl ied by t he b idd er.
Pow er o f any o th er vo ltage (except 4 15 V AC o r 220 V DC), e.g. 24 V DC o r 110 V DC, et c, shall be
arranged by Bidder h imself by provid ing sui table systems. 24V DC supply shal l be through
screened cable to be supp l ied b y the Bidder.
Fol low ing HT cabl ing shal l a lso b e includ ed by t he Bidder apart f rom the abov e:
Technical Specificati on: Electr ical Page 8 of 77
The eart h ing system shal l be pro vided fo r com plete W T SYSTEM plant. The new earth ing system
shal l be connected t o t he exist ing earth ing system.
Bidder shal l also consider earth ing of fo l low ing equipmen t: 33kv substa t ion equ ipment s.
6.6kV WT switchb oard at W T SYSTEM substat io n in sw itchgear cum M CC room
W T LT distr ibut ion tr ansform ers – Neut ral as w el l as bod y earth ing
415 W T SYSTEM PCC at W T SYSTEM substat ion in sw itch gear cum M CC room
Contro l pane l fo r pow er d ist r ibu t ion equ ipm ent a t ex ist ing W T contro l room
LT busduct s
Charger panels, DCDB, etc at W T substat ion in switchgear cum M CC roo m
Bidder shal l consider earth ing r ing mains at each electr ical premise and connect the electr ical
equ ipment wi th the r ings. The ear th ing r ing mains sha l l be connected wi th underground
ear th ing mats to b e prov ided by the Purchaser made o f 2x40m m d ia M S rod. Adequate num ber
of r isers shal l be made avai lable to the Bidder for connection with h is earth ing r ing main. For
t ransformer neutra l ear th ing , b idder sha ll cons ider ded ica ted ear th ing p i ts (m in imum tw o p i ts
per t ransform er) .
Lightn ing prot ect ion shal l be pro vided by t he bidder f or com plete W T SYSTEM including ta l l
insta l lat ions covered under the bat te ry l imi t .
Bidder shal l a lso include complete i l lumination of the premises under the battery l imi t and al lth e above electr ical pr em ises coming at W T SYSTEM substat ion and adjo in ing areas.
Air-condi t ioning, vent i lat ion and exhaust fan s for var ious room s / pr em ises of W T SYSTEM along
w ith t heir com plete electr ics shal l be under scop e of the Bidder. The batt ery and batt ery charger
room shal l be air -condi t ioned. Switchgear cum MCC room of WT substat ion shal l have
pressur ized venti lat ion. Transformer rooms of the WT substat ion shal l have exhaust fans.
Bat te ry and bat te ry charger room of the WT substa t ion shal l be a i r - cond i t ioned.
A l l in te rconnect ion fo r p ow er , contro l and inst rum enta t ion / signa l amongst equ ipment supp l ied
by the Bidder shal l be under Bidder 's scope of work. Simi lar interconnections including power,cont rol and signal betw een Purchaser 's equipm ent and Bidder 's equipm ent shal l be do ne by th e
Bidder . Al l the cable ter m ination s at b oth ends, cable trays and cable accessor ies shal l be un der
Bidder's scope.
2.5 Electrical system de sign criter ia
a) Genera l
The design, manufacture, assembly and test ing as wel l as performance of the equipment shal l
confo rm to th e re levant IS : speci f icat ions ( latest revision) and o th er re levant standard s. In case
the Bidder is not in a posi t ion to comply fu l ly wi th certa in IS speci f icat ions, or in respect of
Technical Specificati on: Electr ical Page 10 of 77
The short c i rcui t rat ings of a l l the equipm ent l ike M CCs, mo tor s, PDBs / LDBs, cables, pow er
socket & l ight ing cabinets, etc shall be selected keeping in v iew t he fau l t level capaci t ies of the
Purchaser ’s e lectr ical equipm ent .
The thre e phase symm etr ical short c i rcui t rat ing at 6 .6 kV level shal l be 43.7kA. The th ree phase
sym m etr ical shor t c i rcui t rat ing at 415 V level shal l be 50kA.
The rat ed short c i rcui t w i thstand du rat ion fo r 6.6 kV shal l be 3 sec, wh ereas for 415 V system , i t
shall be 1.0 sec.
f ) Criteria for select ion of volta ge levels for drive m oto rs
AC squirre l cage induction motors above 160 kW shal l be fed at 6.6 kV from Purchaser ’s
sw i tchboard . M oto rs o f 75 kW and above sha l l be fed f rom M CC through a i r c ircu i t b reakersw i th num er ic type compr ehensive mo tor p ro tect ion re lays. M otor s be low 75 kW sha l l be fed
from M CC through M CCB/M PCB wi th pow er contactor and over load re lay.
g) System Earth ing
6.6kv system is uneart hed 415v system is sol id ly earth ed.
2.6 ELECTRICAL SYSTEM REQU IREM ENTS
M inim um num ber o f spare feeders in each of th e M CC / PDB / LDB / SLDB shal l be 10% subject
to m in imum one no. o f each t ype and ra t ing in each sect ion . The ra t ing and t ype o f spare feeder
shal l be de cided dur ing detai led engineer ing stage.
Sizes and requ irement of var ious pow er and contro l cables shal l be decided and int imat ed to the
Purchaser w e l l in advance to su i t t he app roved scheme/ to ach ieve scheme requ i rement .
Space heater power supply to the motors shal l be fed from the MCC through same cubicle or
through separate dedicated cubicles through 415/240 V transformers. Space heaters shal l be
in ter locked w i th m oto r m ain pow er supp ly . Bidder to subm i t a system w ise dr ive l i st ind ica t ing
requ ired process inter locks, perm issive condi t ions etc. w i th p laces and m ode of con trol , contr ol
system phi losophy with provision of var ious control , indicat ion, measur ing devices at var ious
places. The Purchaser shal l appro ve th is based on above ap proved phi losophy and Bidder shal l
have to p rov ide a ll equ ipment / mat er ials and prepare a contro l schem e/ log ic d iagram wh ich
shal l be ut i l ized for designing the motor feeders at 6.6 kV switchboard and 415 V MCC at
Bidder ’s end.
Above-mentioned control phi losophy and inter locking logic shal l be prepared as per the
Technical Specificati on: Electr ical Page 12 of 77
shal l a lso be operated from local control stat ions for emergency stop as wel l as for decoupled
t r i al r un o f m o to rs.
Fol lowing inter locks / a larm, etc shal l be provided for var ious dr ives/mechanism of cool ing
w ater system :
• W hen conv eyor t r ips, Sizer w i l l t r ips.
• Wh en s izer w i ll t r ip , Apron feeder w i ll t r ip .
• Wh en apron feeder t r ips, Wagon t ipp le r w i l l t r ip .
• Wh en any o f the runn ing dr ive t r ips , the s tandby dr ive sha ll sta r t au tom at ical ly .
• When any of the running conveyor tr ips, the preceding/succeeding conveyor shal l tr ip
automatical ly.
• A conveyor shal l take star t on ly when i t ’s precedin g conveyor star t s
• Auto-Tr ipping of conveyor dr ives through var ious mechanism l ike pul l chord, bel t sway
switch, etc
The above inter locks/alarms and control phi losophy are minimum and indicat ive. The detai led
requ iremen ts for th e above shal l be f inal ized dur ing detai led engineer ing.
Bidder shal l furnish detai ls of control , monitor ing, inter locking, protect ion, annunciat ion and
meter ing system for a l l the HT dr ives for designing the Purchaser ’s equipment l ike 6.6 kV
switchgears. Simi lar ly, control , monitor ing, inter locking, protect ion, annunciat ion and meter ing
system for a l l the LT dr ives duly approved by the Purchaser shal l be ut i l ized by the Bidder indesigning th e M CCs.
B idder sha l l use s ta te o f a r t techno logy wh i le fu l f i l l ing the funct iona l requ i rement o f a l l the
equ ipment fo r smoo th and t roub le f ree opera t ion th rou gh PLC.
Var ious transducers (4-20 mA range) as per requirement shal l be provided to faci l i tate control
and monitor ing from PLC. Required transducers and wir ings to hook up al l analog and dig i ta l
inpu ts / ou tpu ts to / fro m PLC shal l be included in th e scope.
Inter lo cking arrangem ent shal l a lso be f urnished to take care of a l l the app roved logic schem es.
Bidder shal l provide necessary w ir ing, cont rol and requ ired i tem s to achieve th e appr oved logic /scheme. Select ing local / remote switch of local control stat ion in local posi t ion shal l carry out
loca l mo de opera t ion o f t he dr ives fo r test / t r ia l e tc . Perm issive cond i t ions fo r sta r t and t r ipp ing
of var ious dr ives shall be p rovided as per app roved lo gic d iagram s.
A ded ica ted hardw i red contro l pane l / desk shal l also b e prov ided by the b idder a t W T contr o l
room to contro l and m oni to r e lect r ica l power d is t r ibu t ion system .
PROTECTION SYSTEM
Prot ect ions fo r t he d i f fe rent e lect r ica l equ ipment a re en l is ted be low :
Technical Specificati on: Electr ical Page 14 of 77
M oto rs be low 75 kW sha l l be fed f rom M CC throu gh M CCB wi th pow er contactor and over load
relay.
M oto rs o f 5 kW and above but b e low 75 kW , sha l l have fed th rou gh M CCBs (fo r shor t c i rcu i t
p ro t ect ion), num er ic moto r p ro t ect ion re lay l i ke M PR-300 or equ iva len t ( fo r over load and o th erm otor p ro tect ion) and pow er contactors .
For m ot or b elow 5 kW , M PCBs smay be considerd in p lace of M CCBs.
Single phasing prot ect ion shal l a lso b e provided in th e M CC m odu les.
M ETERING
Fol low ing met er ing shal l be prov ided in var ious M CC/DBs;
4 1 5 V M CC
1. 415 V INCOM ER (EACH) • AM M ETER (DIGITAL TYPE)
• VOLTM ETER
• kWH M ETER
2. BUS COUPLER • AM M ETER
3. OUTGOIN G • AM M ETER (DIGITAL TYPE)
M OTOR FEEDER (EACH)
PD B
1. 415 V INCOM ER (EACH) • AM M ETER (DIGITAL TYPE)
• VOLTM ETER 2. OUTGOING (EACH)
• AM M ETER (DIGITAL TYPE)
4.2 LT M OTO R CONTRO L CENTRE (LT M CC)
Construct ional Featu res
Ful ly drawout type with modules having service, test and isolated posi t ions. Floor mounting,
free standing w ith base channel 50 m m high for f ix ing on th e inserts on th e f loor . M CC shal l be
single front , tota l ly enclosed, dust and verm in proo f.
Al l th e m odu le of th e M CCs shal l be spacious to faci li tat e maint enance of equipm ent inside the
m odu le. Pol lut ion d egree appl icable shal l be po l lut ion degree 4 as per IS-13947 (Pt- I) , 1993.
Incom er and bus coupler pane ls
M CC incom ers and bu s coup lers shal l have Air c i rcui t breakers. Incom ers and bu s couplers shal l
be ra ted fo r a t least 125% of maximum demand t ak ing in to account the spare feeders and shal l
be sui table for t he specif ied faul t level .
Incomers and bus coupler shal l be electr ical ly inter locked to prevent paral le l operat ion.
However, a defin i te delay defeat Inter lock switch shal l be provided to faci l i tate paral le l
opera t ion . Auto changeover fac i li ty sha ll a lso b e prov ided bet w een the tw o incomers.
Technical Specificati on: Electr ical Page 16 of 77
Closing and tr ipping of ACB shal l be by closing coi l (operat ing range 85% to 110% of rated
vol tage) and t r ipping by t r ip coi l (operat ing range 70% to 110% of rated vo l tage) respectively.
Bui l t- in d ir ect act ing type m icroprocessor based num erical re leases for sho rt c i rcui t , over curren t
and earth faul t shal l be pro vided.
Auto changeover shal l be done through under vol tage relays and check synchronizat ion re lay
w ith t im e delay. Al l th e re lays shal l be m icroprocessor ba sed num erical re lays.
M oto r p ro tect ion m oulded case c i rcu i t b reaker (M CCB)
The character ist ic shal l match the motor duty appl icat ion. Rated ul t imate short c i rcui t breaking
capaci ty ( Icu) shal l be 50 k A. Ratings selected shall be at least 1 25% of the fu l l load current of the
motor. For smal l rat ing dr ives such as valves, Siemens 3UV13 type (or equivalent) or motor
pro tect ion circui t breaker (M PCB) shal l be used. Ut i l isat ion category shal l be A.
M agnet ic contactors
Pick up shal l be posi t ively at vol tage between 85% to 110% of rated value. For frequently
reversing dr ives, AC 3 rat ing selected shal l be 50% higher t han fu l l load curr ent o f t he m ot or at
the speci f ied duty cycle shal l be provided. For reversib le dr ives, mechanical ly as wel l as
electr ically int er locked cont actors shall be u sed.
Thermal over load re lay
Therm al over load r e lay sha l l be t r ip le po le , amb ient tem pera ture comp ensated, inverse t ime
lag, hand reset type, b im etal l ic w i th ad justable sett ing and bui l t in single phase protect ion. The
re lay sha ll be ab le t o w i thstand p rospect ive shor t c ircu i t -cur ren t w i thout damage or in ju r ious
heating t i l l the m ot or pro tect ion M CCB clears th e faul t . Tr ipping indicat ion and reset push
but t on op erab le f rom out s ide sha ll be prov ided.
Push Button s / Indicat ing Lam ps / Indicat ing instrume nts
Push but ton s shal l be spr ing ret urn, pu sh to actuate typ e and their con tacts shal l be sui table to
carry and break 240 V AC, 10 A and 220 V DC, 1 A. Indicating lamps shall be LED LVGP (Low
Voltage Glow Prot ect ion up t o 100V) type. Standard colou rs shal l be appl icable for pu sh but ton s
and for indicat ing lamps. Indicat ing instruments shal l be f lush mounting, square dia l wi th 900
scale wi th zero adjust ing device for external operat ion. Accuracy class shal l be 1.0 or better .
KW h m eter sha ll a lso be prov ided w i th incom ers.
M CC sha l l have run / sta r t , s top , t r ipped, and r eady to sta r t push bu t to n cum ind ica t ion lamp for
m otor feeders.
Current t ransformers
The thermal and dynamic stabi l i ty current for CTs and CT rat io shal l be as per requirement.
Pro tect ion and measur ing cur rent t ransformer sha l l be bar p r imary/ w indow type wi th 1Asecondary. Burden o f CTs shal l be as required b y t he associated m easur ing equ ipm ent.
Technical Specificati on: Electr ical Page 17 of 77
Potent ia l t ransformers
Pot ent ia l transform ers shal l be prov ided on in comers as wel l as on b uses and shal l be in same
circuit breaker cubicle. 415 V side of PTs shall have fuses. Accuracy class 1.0 shall be used. VAburd en shal l be selected based on m eters and relays connected w ith t he PT.
Control transformer
Control transformers shal l be dry type 415V/240V, pr imary taps at +2.5 %, +5 % and shal l be
m ount ed in d rawou t t ro l ley i f ou t go ing feeders are in d raw out execut ion . Cont ro l supp ly shal l
have supervision faci l i ty, a larm shal l be provided for non avai labi l i ty of any one of the control
supp ly. Aut om atic/m anual changeover faci l ity shal l a lso b e provided. Aut o-changeover shal l be
blocked i f pow er supp ly to r espective sect ion is not avai lable.
For capaci ty considerat ion of control transformers, each shal l be capable to meet 100 % load
including spare feeders and 10 % cushion for fu tur e and 15 VA for each mo dule fo r rem ot e aux.
re lays and indicat ion lam ps. Separate DC and AC contr ol (3 ph & neut ral) copp er busbars shal l
be considered for each M CC. From AC contro l bus, m ot or space heater supply shal l be tap ped
w i th su i tab le contro l and in ter lock ing ar rangem ent .
DC Cont rol sup ply
DC supp ly is required for e lectr ical ly cont rol led ACBs. For t w o sect ions, tw o DC bu ses shal l be
th ere. In bu s coupler panel , manual sw itch shal l be there for changeover of one supply to o ther
section. Non -avai labi l i ty of D C supp ly shal l be annunciated in M CC or n earby contr ol room .
In ternal Control W ir ing and external Terminat ions
Internal control wir ing shal l be by 660V grade PVC insulated, single core stranded copper
conduct or o f m inimu m cross sect ion 2.5 sq.mm . for CTs and space heater ci rcui ts and 1.5 sq.m m
for ot her ci rcui ts. For CT secondary w ir ing, d isconnecting t ype term inal b locks (CAD t ype) shall
be considered.
For external terminations, DIN rai l mounting type bakel i te type terminal b locks shal l be used
complete wi th insulated barr iers, stud type terminals, washers, nuts and lock nuts andidenti f icat ion str ips. Pow er and contro l term inals segregated.
Ot her a ccessories
Fol low ing item s shal l be provided f or t he M CCs und er th e scope of th e Bidder:
Breaker l i f t in g/h andl ing tro l ley ( for ACBs) : 1 N o. per M CC Room
Breaker racking hand le (fo r ACBs) : 4 No s. per M CC Room
Panel key (if app licable) : 5 No s. per M CC Room
Select ion o f pow er compo nents & w i r ing fo r cont inuous dut y cage moto r d r ives is given b e low :
Technical Specificati on: Electr ical Page 24 of 77
The l imit ing value of vol tage at rated frequency under which motor wi l l successful ly star t and
accelerate to rated speed with load shal l be assumed to be a constant value of 80 % rated
vo l tage th roughout t he s tar t ing per iod .
A l l mot ors sha l l be supp l ied w i th fou ndat ion b o l ts ( if app l icab le), d ra in h o les w i th p lugs. M oto rssha l l be des igned fo r 5 0oC amb ient t empera ture .
M ot ors supp l ied shal l be com plete w i th requ ired doub le com pression cable glands, cr imp t ype
cable lugs and f i rst f i l l ing of lubr icat ion, nam e plate, etc. Li f t ing faci l ity t o b e provid ed for a l l HT
motors and big size LT motors. Guards shal l be provided to prevent accidental touch for
coupl ings and fo r free shaft end s shal l be pro vided.
Degree of p rot ect ion for m oto r and bear ings shal l be IP-55 for indoo r and IP55 w ith ra in canopy
and w eather p roof construct ion fo r ou tdoor . M oto r sha l l be su i tab le to w i thstand a t least t h ree
successive star ts f rom system co ld cond i t ion and tw o s tar ts f rom hot cond i t ion a t n orm al system
voltage and fr equency.
The dr ive mot or sha l l have at least 15 % marg in over the maximum pow er requ i rement o f the
dr iven equ ipm ent af ter consider ing all losses, de-rat ing du e to tem peratu re and specif ic si te and
operat ing condi t ions.
The m oto r m ay be sub jected to sudden app l ica t ion o f 150% ra ted vo l tage dur ing bus t ransfer,
due t o phase d i f fe rence betw een the incom ing vo l tage and m oto r res idua l vo l tage.
M otor h andl ing faci li ty and canopy
Handl ing faci l i ty and space shal l be provided for a l l the HT and LT motors. Mono rai l shal l be
prov ided and sha l l be extended up to open main tenance space fo r each o f the HT motors .
Canop ies made o f GI sheet o f min imum th ickness o f 2 mm sha l l be prov ided to each o f the
HT/LT mot ors loca ted ou tdoor .
Al l motors, in general , including conveyor motors shal l be 4 pole construct ion, hence speed of
maximum 1500 rpm. However , motors fo r t rave l d r ives o f yard mach ines sha l l be o f 6 po le
construct ion , hence speed o f 1000 rpm .
LOW VOLTAGE INDU CTION M OTORS
Frame sizes shal l be as per IEC. Casing feet shal l be inte gral wi t h t he m oto r bo dy. For mo tor of
rat ing up t o 5 kW , ball bear ings shal l be used fo r bot h DE & NDE end. For rat ings above 5 kW the
DE end shal l be provided with bal l /ro l ler bear ing and NDE end shal l be provided with bal l
bear ing. Bear ings shal l be sui tab le for running of m oto r in e i ther d irect ion . M oto rs 110 kW and
above shal l be provided with bear ing temperature indicators. Explosion proof/ increased safety
design fo r explosion hazardou s areas as per r equirem ent .
Terminal bo x shal l be of sui table dim ension t o r eceive alum inium cables and shal l be ro tatab le
Technical Specificati on: Electr ical Page 31 of 77
d isconnected wh enever any one o f the s ides o f the enc losures are opened w i th the t r ansform er
in energized condi t ion.
Suff ic ient precaution s shal l be t aken so th at d oor s are closed f u l ly. Door locks shal l be p rovided
and keys shal l be u niversal typ e.
4.7. 5 Of f-Circuit Links
The off-ci rcui t tapping l inks shal l be provided on the HV side with appropr iate register p late to
show th e l ink location. The l inks shal l be pro vided w ith a separate do or f or access. The do or shal l
be pro v ided w i th appropr ia te sa fe ly lim i t sw i tches wh ich w i l l t r ip t he t ransform er HV / LV s ides
in open cond i t ion .
4.7.6 Cooling
The cool ing system for d ry typ e transform ers shal l have Air-Natural (AN) cool ing.
4.7.7 Ne utral Bushing Current Transform ers
CTs for b ack up earth fau l t (51N) as w el l as fo r restr icted earth faul t (64) shal l be prov ided on the
neutra l end.
Neutral bushing CT shal l be removable at si te wi thout opening transformer tank cover/act ivepar t . Secondary leads o f 4 sq .mm sha l l be brought to a weatherproof te rmina l box and f rom
there t o th e marshal ling box.
Neut ral bushing CTs of sui table rat io, c lass and adequate bur den shal l be pro vided by t he Bidder
to ca ter to the requ i rement o f a l l s tandard pro tect ion assoc ia ted wi th the t ransformer o f th is
capacit y. CTs for REF shall b e PS class.
4.7.8 M arshall ing Box
Enclosure mounted marsha l l ing box to be supp l ied wi th a l l contro ls ins t ruments, p ro tect ion ,
accessor ies & f i t t in g as required fo r t he transform er and i t s associated anci l lar ies. The box shal lbe made o f 2 m m sheet s tee l w i th IP 54 degree o f p ro t ect ion .
Sheet steel marshal l ing box of dust-proof design shal l be provided to accommodate
temperature measurement as wel l as control system, as may be necessary. The box shal l be
m oun ted on t he transform er enclosure and shal l be pro vided w ith inte rnal light ing, space heater
and th ermosta t w i th t he i r contro ls accessib le f ro m out side .
The box shal l be provided with sui table hinged steel doors at the front and al l equipment shal l
be so placed as to accessible from th e fron t. Provision shal l be m ade for pad locking the door s.
Sui tab le glazed w indow s shal l be provided at appro pr iate po sit ion s to g ive an unr estr icted viewof th e tempera ture ind icators e tc , w i thout open ing the door .
Technical Specificati on: Electr ical Page 32 of 77
Al l in i t ia t ing “ contacts” o f sha ll be w i red up t o t he te rm ina l b lock in the bo x. Al l cont ro l w i r ing
shal l be w ith 1 .1kV grade stranded PVC insulated arm our ed copper cable of 2.5 sq.mm . Term inal
blocks shall have 20 % spar e capacity.
The externa l connect ions betw een th e apparatus on the t ransform er and th e m arsha l ling boxshal l be don e w ith sui table heat r esist ing copp er conduct or cables of co re size no t less th an 2.5
sq. mm. The cables required to connect the marshal l ing box and transformer accessor ies shal l
be adequately protected against mechanical damage. There shal l be no jo ints or tappings
betw een two te rm inat ions o f any cab le . Not m ore than tw o te rm inat ions sha l l be made a t any
one terminal . Al l terminations at var ious devices and terminal b locks shal l be provided with
plast ic ferru les having engraved numbers. Al l terminals and l inks shal l be so arranged as to
faci l i tate easy checking and test ing of re lays, instruments etc. Provision shal l be made for
term ination o f pow er cables as w el l as mult i -core cont rol cables in th e marshal l ing box.
The control c i rcui t terminal b locks provided for external cable connections shal l be provided
with screw type terminals and shal l be complete wi th terminal screws, l inks, cable carr ies etc,
Each t erm inal b lock shal l have 20% spare t erm inals and al l w ir ing shall be such t hat i t is easi ly
identi f iable and accessible fo r m aintenance.
Al l devices, wires and terminal b locks with in the marshal l ing box shal l be clear ly identi f ied by
sym bo ls correspon ding to t hose used on relevant schem atic or w ir ing diagrams.
En closure class o f m arshall ing bo x shall be IP-55.
Terminal Arrangem ent H V/LV term inals shall be sui table for cables considered.
4.7.9 Transformer Fit t ings & accessories
Each t ransform er shal l be f i t t ed w ith a l l stand ard and special f i t t ings and accessor ies and shal l
inc lude but no t be l im i ted to t he fo l lowing:
• Inspection covers.
• Off ci rcui t l inks in th e pr im ary for vo l tage var iat ions.
• Rating, d iagram and tap connection p lates.
• Term ina l mark ing p la te
• Two nos. ear th ing te rm ina ls wi th lugs.
• Wind ing tempera ture detectors wi th microprocessor based Tempera ture scanners wi th
d ig i ta l read out and requ is i te se t o f remote s igna l ing contact fo r a la rming/ t r ipp ing
opera t ion .
• Under carr iage with b i-d irect ional ro l lers w i th locking and bol t ing devices.
• M arshal l ing box com plete w i th a l l instru m ent s, accessor ies and f i t t in gs as required fo r th e
t ransformer .
• Off load t ap changers w i th posi t ion indicator s and pad locking faci liy
• Neut ral bushing CTs w ith t erm inal arrangem ent
Technical Specificati on: Electr ical Page 42 of 77
4.11 UN INT ERRUPTIBLE POW ER SYSTEM (UPS)
Genera l System Descript ion
The required kVA, 50 Hz, single phase UPS system shal l provide continuously operat ingunin terrup ted p ow er supply to cr i t ical AC loads such PLC, instrum entat ion, etc.
The capaci ty of UPS shal l be sui table t o feed po w er requirem ent of the PLC wh ich shal l cont rol
and m oni to r a l l the dr ives/ m echan ism o f p roposed add i t iona l coa l hand l ing system .
The UPS system shal l include but n ot n ecessar i ly lim i ted t o t he fo l low ing equip m ent :
• One 100% ra ted bat te ry bank
• One set of Float Charger (FC) and o ne set o f Float cum Boost Charger (FCBC) comp lete w i th
associated incoming AC sw itchgear.
• Two nos. 100% capaci ty invert er banks.
• One no . DC switchgear, connecting above and also inverter b anks stated above
• One no. 3 phase to 1 phase transformer and associated AC switchgear, 230V, 1 phase
vol tage stabi l izer and backup source stat ic swit ch.
• One no. 24 0 V UPS ACDB
• One no. four w ay manual bypass sw itch
• Stat ic switches
• All inte r connecting cables/w ir ing w ith conn ection accessor ies and ot her required i tem s tom ake the system com ple te .
M ode o f Opera t ion
N o r m a l M o d e
During the normal operat ion the UPS shal l be used to provide power to the cr i t ical loads. The
pr imary AC source shal l be used to supply power to the rect i f ier charger. Two (2) no. chargers
shal l feed regulated DC po w er to t heir individual inverter ban ks and simult aneously f loat charge
th e backup batt er ies.
Em ergency M ode
Upon fa ilu re o f p r imary AC source supp ly ing th ree phase pow er to the bat te ry chargers, the
input po w er to the inver te rs sha l l be supp l ied f rom the back up bat t e r ies. W hen th e AC pow er is
restor ed, input pow er fo r the inver te r and pow er fo r recharging the bat te ry sha ll au tom at ical ly
be suppl ied from the rect i f ier charger. The batter ies shal l supply the inverter whenever the
chargers are unable to supply the sudden load demand or their response to the load change iss low.
Technical Specificati on: Electr ical Page 45 of 77
Outpu t o f the un in t er rup tab le pow er supp ly system w hi le de l iver ing a load o f i ts ra ted capaci ty
(P.F of load shal l not effect i ts ou tpu t) shal l have fo l lowing var iat ions;
Vol tage regulat ion :1% (For 0-100% load)
Frequency : (+/-) 0.5% (For 0-100% load)
Eff ic iency :Above 80%100% to 0% and 0% to 100% load : Vol t d ip +10%
Enclosure an d ven tilat ion
Enclosure confo rm ing to IP-41 class. Uni ts shal l be pro vided w ith coo l ing fans and lou vers at t he
bot to m sides. Ind ividual venti lat ion du cts for each uni t shal l be pro vided.
Distribut ion Board
The DB shal l have tw o b uses, main and standby and shal l be prot ected by semicondu ctor f uses
with fuse monitor ing device, bus heal thy lamps, vol tmeters and ammeters. Each load shal l befed by t w o ind ependent feeders. Isolat ing and buscoupl ing sw itches shal l be prov ided.
The enclosure sheet steel th ickness shal l be 2.0 mm . with cold ro l led sheets and 2.5 m m for ho t
ro l led sheet s and enclosure class prot ect ion shal l be IP-54.
TECHN ICAL PARTICULARS
1. Appl icat ion : Un inter rupt ib le Pow er supp ly for PLC and oth er essentia l loads
2. Capacity : 200 % of PLC load
3. Degree of pro tect ion : IP 54
4. Cable entr y : Bott om
5. Input Supp ly Vol tage : 415V+/ - 10%, 3 phase 4 w ire, 50 Hz +/ - 5%
Bat ter ies
1. Type : VRLA, SM F
2. App lication : UPS System
3. Numb er of cells in each bank in ser ies : As per requ irement
4 . Ambient tem pera ture : M in . temp . :5 .0 deg.C M ax.tem p. :50 deg. C
5. D.C. nom inal system vol tage : Sui table to inverter system
6. Ampere hour capaci ty : B idder to fu rn ish a long w i th calcu la t ions7. Charging m etho d prop osed : . Float and bo ost
8 . Em ergency load dura t ion : 60 M inutes (ba t te ry back up t ime)
9 . Cont inuous load/ dura t ion : As per requ i rement
Battery chargers
1. Num b er req uired : 2 nos. (1 FC + 1 FCBC)
2. Type : Stat ic
3 . M ethod o f charging : F loa t and boost charge type
4. DC system vol tage : To sui t th e system
5. Auto m atic vol tage regulator requ ired(AVR) : Yes6. Regulat ion w ith AVR : +/ -1%
Technical Specificati on: Electr ical Page 47 of 77
The resisto rs shal l be assem bled on high qual i ty asbesto s or m ica insulated high ten si le steel t ie
rods and separated from one another by mica or asbestos washers in required numbers and
r ig id ly supported to e l iminate vibrat ion, breakage, d isplacement or deformation. Tappings shal l
be pro vided w ith every resistance elemen t indicat ing resistance value to enable adjustm ent s, if
requ ired. Individual gr ids shal l be TIG welded at t he junct ions and term inal taps shal l be w eldedto gr ids, ensur ing a consisten t curr ent pat h.
The gr ids shal l be assem bled o n h eavy steel fr am es wh ich shal l be sui tably stacked, hou sed and
mounted in minimum 2.5 mm CRCA sheet steel enclosed cubicles wi th louvers along with wire
m esh t o ensure good vent i lat ion and m oun ted o n a base fram e of ISM C 125 . The panel of
res is to r un i ts sha l l be f ree s tand ing, f loor mount ing type and prov ided wi th two numbers o f
ground ing pads, tapped ho les and bo l ts su i tab le fo r connect ion o f g round ing conductor o f 50x6
m m G.I f lat. Enclosure shal l be in single front execut ion.
Individual banks shal l be mo unt ed on b racket w elded to t he fram e, as such individual bank can
be wi thdrawn out f rom enc losure wi thout d is tu rb ing o ther banks. A l l res is to r banks sha l l be
pro vided wit h adequat e li f t ing faci l ity fo r handl ing dur ing instal lat ion and o ver haul ing.
The t erm inals shal l be brought out in th e separate term inal box ( IP-55) on one side and m arked
w ith m etal l ic tags for ext ernal connection w ith AYFY cables.
The current carrying capaci ty of the resisto r shall be so selected that th e tem peratu re shal l not
exceed 370 d eg. C.
4.13 PLANT ILLUM INATIO N SYSTEM
The scope includes com plete p lant i l lum ination system t o achieve required i l lum ination levels as
per IS or as per CBIP guidel ines. The scope shal l cover th e fo l low ing i l lum ination system s:
• No rmal AC l ight ing
• DC Em ergency l ight ing. M aintenance l ight ing
• Per iphera l, road/ st ree t and area l igh t ing w i th in ba t t e ry l imi t
I l lum ination shal l be p rovided in a l l the fo l low ing prem ises:
Technical Specificati on: Electr ical Page 49 of 77
Sufficient numbers of LDBs, SLDBs, l ighting poles, 415/240 V switch socket outlets, ceil ing fans
w ith r egulato rs, earth ing pi t s, M CB cont rol led socket ou t let , junct ion bo xes, etc shal l be
considered und er scope o f the B idder as per actua l requ i rement .
DC emergency l ights shall be fed from separate DCELDB. Similarly, power receptacles shall befed fro m ded icated Receptacles DB. DCELDB at W T SYSTEM substat ion shall be f ed f rom
Purchaser’s DCDB. Receptac le DB shall be fed fro m Bidd er’s PDBs/au x. PDBs.
Sufficient numbers of DCELDBs and Receptacles DBs shall be considered by the Bidder as per
requ i remen t .
LIGHTING DISTRIBUTION BOARD (LDB)
415V, 3 phase, 4 wire, 600A, 50 kA (shor t t im e rat ing for 1 sec.) indoor type .
Board shal l be single front, metal c lad, front matched, free standing, f loor mounted, dust and
vermin proof, non-draw-out, fu l ly compartmental ized and extensible on both sides, IP54 type
enclosure. Incom ers shal l be draw out typ e. LDBs shal l have a ser ies of panels of un i form height
placed side by side having front access for operat ion as wel l as cabl ing and access for
m aintenance of busbars. LDBs shal l have tw o incom ers and o ne bu s coup ler.
Separate bu sbar compar t m ents prov ided on t he to p sha ll have bo l ted covers in t he f ron t and
rear. The main busbars shal l have continuous current rat ing as required. The rat ing of the
neutral busbar shal l be 50 % of the phase busbars. The busbars shal l be of a luminum al loy
conforming to IS 5082. The busbar sizes shal l be so selected that wi th the passage of rated
cur rent , the tempera ture r ise over 500C ambient does not exceed 400C as measured by
the rmomete r .
Each cubicle shal l have segregated feeder compartments arranged in t ier formation with each
compar tm ent hous ing one feeder c i rcu i t w i th lockab le h inged door hav ing neoprene gasket a l l
around . M odu lar con str uct ion shal l be adopt ed to cater fo r d i f ferent sizes of feeders. The
cubicles shal l have com m on h or izontal busbar chamb er at th e top and vert ical r isers at t he back.
The cab le compar tment sha l l be prov ided on the s ide wi th cab le en try a r rangement f rom
bot t om . The bu sbar and cab le com par tm ents sha l l be prov ided w i th bo l ted cover p la tes. The
rear cover shal l be easi ly rem ovable typ e construct ion .
The LDBs shal l conform to IS 8623 fo r factor y bui l t assembl ies, IS 13947 f or general requ irem ent
of sw itchgear and IS 5578 & IS 11353 – Guide for m aking and iden ti f icat ion of conducto rs and
apparatus term inals.
The LDBs shal l be fabr icated f rom CRCA sheets w i th 2 m m th ickness for a l l me m bers except th e
doo rs of the m odu les, the rear covers, th e covers of cable cham ber s and busbar chamb ers which
m ay be o f 1 .6 m m w i th adequate s t i f feners to pr event buck ling . Non- load bear ing par t i t ion wa l ls
Technical Specificati on: Electr ical Page 51 of 77
temperature compensated bi-metal over load releases and a magnetic short-ci rcui t re lease with
inverse t im e character ist ic. Releases shal l be ei ther stat ic or m icroprocessor based.
The opera t ing hand le sha l l be inc luded w i th m odu le door such tha t the doo r can be opened on ly
w i th t he breaker in the “ OFF” pos it ion . The M CCB hand le a f te r th e breaker t r ipped due t o a fau l tshal l occupy an intermediate posi t ion. The breaker shal l be capable of interrupting a fu l l faul t
current co rrespon ding to th e faul t level speci f ied.
M CCBs shal l have a breaking capaci ty o f 50 kA at 4 15V. Curr ent l imi t in g M CCBs are n ot
pe rm i t ted .
The LDB shall be con sisting of f ol low ing feeder s:
Incom er : 2 Nos. each of 600 A M CCB
Bus coupler : 1 No. of 600 A M CCB
Out going : 125 A M CCB – 6 Nos.
63 A M CCB – 10 Nos.
SU B LIGHTIN G DISTRIBU TION BOARD (SLDB)
415V, 3 phase, 4 wire, 125/63A (as appl icable) , indoor/outdoor type (as appl icable) general ly
confo rm ing to IS 13947 and IS 8623 as appl icable.
The SLDB shal l comp rise of on e num ber o f incom ing TPN M CCB, th ree no s. of DP M CBs, and
requ isite n um be r of ou tgo ing SPN M CBs (as sp ecified) and adequ at ely rate d bu s bars. The SLDBs
shal l a lso have t im er, contacto rs, A/ M sw itch, etc as per requirem ent. The enclosure class of
SLDB shall b e IP 54. The te rm inals of M CCB shall be fu l ly shro ud ed. The bo ards shall b e of
indu str ia l , tot a l ly enclosed dust-proo f, w al l mou nt ed, sheet steel cubicle design. The th ickness of
the sheet steel shal l be 2 mm. The boards shal l have welded back and sides and gasketted
h inged door a t the f ron t w i th door hand le and su i tab le lock ing dev ices. For boards wi th
incoming isolat ing switch the access to the operat ing handle shal l be from the front of the
cubicle wi thout opening the front door. Operat ing knobs of outgoing MCBs shal l be accessible
only after opening the front door of the cubicle. Protect ive insulated cover p late shal l be
provided inside the cubicle to shroud al l the l ive parts wi th only the operat ing knobs of the
M CBs prot rudin g outside the cover p late . The board s shal l a lso be d ust-proof in doo r-open
posi t ion . Adequate space sha l l be prov ided wi th in the boards to fac i l i ta te te rminat ion o f
incoming and outgoing cables. The boards shal l be factory wired and assembled. Where
speci f ical ly cal led for , the boards shal l be of special weather-proof design sui table for outdoor
instal lat ion.
The miniature ci rcui t-breakers (MCBs) shal l be heat resistant p last ic moulded type general ly
designed, m anufactur ed and tested as per IS 8828. Un less speci f ied ot herw ise al l M CBs shal l be
prov ided w i th qu ick break t r ip f ree mechan ism and d i rect act ing thermal over load and sho r t -
ci rcui t t r ip e lem ents. The sho rt-ci rcui t b reaking capaci ty o f th e M CBs shal l not less than 9 kA at
0.8 pow er factor . Single-phase M CBs wh ich are n ot p rovided w ith bui l t- in phase barr iers, and
Technical Specificati on: Electr ical Page 52 of 77
mounted ad jacent to each o ther and connected to d i f fe rent phases, sha l l be prov ided wi th
adequat e insulated ph ase barr iers, shall be selected fr om standard current rat ing.
The TPN busbars shal l have continuous current rat ing as required. The busbars shal l be of
copper and sizes shal l be so selected that wi th the passage of rated current, the temperaturer ise over 500C am bient d oes not exceed 400C as m easured b y therm om eter. The m inimum size
of busbars shal l be 25 x 3 mm. The busbars shal l be proper ly supported with h igh qual i ty non-
hygroscopic, sel f ext inguishing and f i re retardant insulat ing mater ia l of adequate mechanical
strength so as to wi thstand, wi thout damage, effects of avai lable short c i rcui t current. The
busbars shal l a lso be prop er ly spaced to faci li t ies moun ting of M CBs and t aking connections to
individual uni t s.
Detachable cover p late shal l be provided at top and bottom for cable glands sui table for PVC
insu la ted , PVC sheathed arm oured a lum inum conductor cab les or fo r d i rect en try o f condu i t .
Cable terminals shal l be sui table for a luminum conductor cables and so arranged to enable
connect ing o f each c ircu i t w i thout d istu rb ing any o ther c i rcu i ts.
Identi f icat ion labels, inscr ipt ion plates, danger boards, etc shal l a lso be provided as per
requ iremen t. Eart h ing arrangemen t and danger p lates shal l be as speci f ied.
SLDBs shal l have auto m atic group switch ing arrangemen t fo r wh ich t imer o f robu st construct ion
and sui tab le con tactor s shal l be provided in each bo ard. Bypass arrangemen t of t im er in form of
auto / manu al sw itch shal l a lso b e provid ed in th e SLDBs. The cont rol ler shal l sense th e out doo r
l ight and shal l sw itch “ ON” th rough auxi liar ies contact s w hen t he sunl ight fa l ls bel low a present
value. I t shall rem ain in th is posi t ion t i l l daw n w hen i t shal l switch “ OFF” wh en th e sun l ight
rem ains a preset level .
Sui tab ly engraved identi f icat ion labels and inscr ipt ion plates shal l be pr ovided for each circui t .
The same shal l a lso be p rovided fo r th e boards.
One cont inuous G.I eart h bu s shal l be provided in the bo tt om part o f SLDB along the f u l l length
of th e board w i th tw o bo l ted type ear th ing te rm ina ls to com ply wi th th e requ i rem ents o f Ind ian
Electr ic i ty Rules. Prop er danger p lates shal l a lso be p rovided on each board .
Each SLDB shal l be provided with padlocking faci l i ty wi th suff ic ient number of keys. The
fol low ing typ es of SLDBs shal l be p rovided:
SLDB, Type A (To b e used fo r 2x40 W FTL l ight fi t t in gs)
Incom er : M CCB, 4 POLE, 63 A : 1 No .
Out going : M CB, DP (63 A) : 3 Nos.
Out going : M CB, SPN (10 A) : 10 No s./ Phase (Total 30 Nos.)
SLDB, Type B (To b e used fo r 250 W HPSV/ M H l ight f i t t ings inside th e bui ld ing)
Technical Specificati on: Electr ical Page 53 of 77
Out going : M CB, DP (63 A) : 3 Nos.
Out going : M CB, SPN (16 A) : 6 No s. per pha se (Total 18 Nos.)
SLDB, Type C (To be used fo r 250W / 150W / 70 W HPSV/ M H l ight f i t t ings out side bu i ld ing)
Incom er : M CCB, 4 POLE, 63 A : 1 No .
Out going : M CB, DP (63 A) : 3 Nos.
Out going : M CB, SPN (20 A) : 5 No s. per pha se (Total 15 Nos.)
SLDB, Type D (To b e used for 250 W HPSV/ M H street l igh t f i t t in gs)
Incom er : M CCB, 4 POLE, 125 A : 1 No .
Out going : M CB, TPN (63 A) : 8 No s.
Suff ic ient num ber o f SLDBs of d i f feren t t ypes (A, B, C and D) shal l be used as per requirem ent o f
di f feren t areas and sub-areas of t he coal handl ing plant. Exact qu ant i ty o f SLDBs of var iou s types
shal l be f inal ized du r ing detai led en gineer ing. Bidder shal l consider as per r equirem ent subject
to m in imu m one num ber o f each type o f SLDB.
RECEPTACLE D ISTRIBUTIO N BO ARD
Receptacles DB shal l be sui t able for 415V, 3 phase, 4 w ire, 125 A, indoor typ e.
Board shal l be single front, metal c lad, front matched, dust and vermin proof, draw-out, fu l ly
com part m ental ised and extensible on b oth sides, IP54 ty pe enclosure.
Sha l l have iso la ted busbar chamber fo r m ain bu sbar a t t he t op , runn ing th rou gh ou t t he length
of t he board . Cham ber shal l have remo vable cover.
Busbars shal l have same cross sect ion t hro ugh ou t t he length . Rating of th e neut ral busbar shall
be 50% of th e main busbar . Ear th bu s bar sha l l run in bo t to m chamb er th rou ghout t he length o f
the pane l.
Shal l have M oulded case circui t breaker (M CCB) tr ip le pole, air break typ e w ith ind ependent
m anual quick make and q uick break type . M CCB shal l be capable of b reaking rated current at 0.3pf at rat ed vol tage. M CCB shal l wi th stand th e faul t current envisaged for 415V system .
General ly a l l boards w i l l have fo l low ing feeder arrangement .
Technical Specificati on: Electr ical Page 62 of 77
The wal l th ickness of each sect ion shal l be designed to wi thstand the loads to which the high
m ast sha l l be sub jected to , bu t shal l no t be less than 8 mm for base sect ion and 6 m m f or o t her
sect ions and m in imu m base d ia sha l l no t be less than 530 m m .
Connection between the var ious sect ions, shal l be achieved by te lescopic sl ip jo ints, theover lapping length being at least 1600mm sl ip jo int assembly shal l be perform at si te. Shaft
sect ion shal l not be jo ined by circum ferent ia l w eld or bol t in g at si te.
The base plate shall be free f rom laminat ion and shal l be single f lange construct ed w ith ho les j ig
dr i l led for anchor bo l ts passage. The bot to m of th e base m ast sect ion shall be secure ly welded
to the base p la te by comple te penetra t ion f i l le t we ld ing . The we lded connect ion o f the base
p la te to the m ast sect ion sha l l fu lly deve lop the st rength o f t he sect ion .
The b ase sect ion shal l be equipped w ith a h inged service door. The service doo r op ening shal l be
comple te wi th a c lose f i t t ing weatherproof and equ ipped wi th a vanda l res is tan t lock. The
service door shal l not be smal ler than 1400 mm x 300 mm the opening shal l be re inforced by a
th ick stee l door f rame.
Base plate of sui table dimensions and th ickness, d iameter, s ize and the placement of anchor
bol t s shal l be determ ined by calculat ions. Anchor bol ts shall be of deform ed steel
re infor cement bars having th e adequate character ist ics w .r . t . tensi le stren gth.
W eld ing o f t w o or m ore anchor ro ds o f shor te r lengths to ach ieve the des ign length sha ll no t be
permi t ted . No w e ld ing sha l l be a l low ed on th e anchor rod bod y.
Adequate earth ing and earth ing terminal shal l be provided with in the access door area of each
M ast. All h igh m ast shal l be ho t d ip galvanized, in accordance w ith IS 2629 / TR 7 Timer con trol
panel shal l be provided w ith over load and single phase prevento r. Timer cont rol panel shal l be
ou tdoo r t ype .
M otor capacity of the w inch
M oto r sha l l be o f ho is t du ty and o f adequate capacity w i th 15 % min imum marg in over
m echan ica l pow er requ i rement . M in im um capaci ty o f 2 .2 kW sha l l be considered .
4.15 EARTHING AN D LIGHTNI NG PROTECTION
EARTHIN G PROTECTION
Bidder shal l include comp lete earth ing of WT substat ion, M CC roo m s, W agon t ipp ler ,
apron feeder, s izer & conv eyor dr ives etc. The und erground earth ing m ats
also shal l be don e by the Bidder . Risers shall be avai lable at a l l th e prem ises for
in te rconnect ion o f own ear th ing network. However , B idder sha l l p rov ide comple te separa te
ear th ing fo r t ransform er neutr a ls.
Bidder shal l include t he fo l low ing in each and every substat ion :
Technical Specificati on: Electr ical Page 63 of 77
1. Eart hing r ing mains at W T substat ion and al l th e electr ical room s/p rem ises
2. Equipm ent ear th ing
3. Transform er neut ra l ear th ing prov id ing ded icated p i ts
Bidder shal l include com plete eart h ing mat er ia l including earth ing str ips, earth electrod es otheraccessor ies for treated earth pi ts, etc. and carry out earth ing r ing mains, earth pi ts,
inter connection s, equip m ent ear th ing, a l l associated civi l w ork s, etc at a l l the ub stat ions.
Al l th e connection s of eart h ing r ing mains w ith avai lable undergroun d earth ing gr id of respective
substat ion / prem ise shal l be under scope of t he Bidder .
Separate dedicated tr eated earth pi ts shal l be provided fo r tran sform er neut rals. Tw o nos. such
earth pi ts shal l be provided for each of the transformers. The treated earth pi ts shal l be
consist ing o f 3 m tr 65 NB GI p ipes, funne ls, c lamps, 3 mt r long 40 m m M S rod e lect rodes, M S
cover w i th l i f t ing lugs, associated civi l wo rks, etc.
Al l the equ ipm ent located in t he W T prem ises / sub-pr em ises e.g. 6.6 kV swit chboards, LT PCCs,
bu sdu cts, tran sform er b odie s, charger p anels, DCDBs, LDBs, SLDBs, recept acles, con tr ol pan els,
M CCs, etc shal l be conn ected by t he Bidder w i th earth ing r ing mains at least tw o d i f ferent
po in ts .
Electr on ic earthin g shall be considerd fo r PLC, etc
Bidder shal l a lso consider earth ing of fo l lowing equipment to be instal led by the Purchaser in
separate cont ract.
• 6.6kV W T sw i tchboard a t W T substa t ion in swi tchgear cum M CC room
• W T distr ibu t ion t ransform ers (2 nos.) – Neut ral as w el l as bod y earth ing
• 415 W T SYSTEM PCC at W T SYSTEM substat ion in sw itch gear cum M CC room
• Cont ro l pane l fo r pow er d ist r ibu t ion equ ipment a t ex is t ing W T cont ro l room
• LT busdu cts (2 sets)
• Charger panels, DCDB, etc at WT substat ion in sw itchgear cum M CC room
Bidder shal l consider earth ing r ing mains at each electr ical premise and connect the electr icalequ ipment wi th the r ings. The ear th ing r ing mains sha l l be connected wi th underground
earth ing m ats (consist ing of 2x40M M dia to be instal led by th e purchaser) . For t ransform er
neutral earth ing, b idder shal l consider dedicated earth ing pi ts (minimum two pi ts per
t ransformer) .
Bidder shal l include complete earth ing mater ia l including earth electrodes, r isers, GI earth ing
str ips, ot her accessor ies, etc. and carry out main earth gr id m at, earth ing r ing mains, earth p i ts,
r isers, interconnections, equipment earth ing, a l l associated civi l works, etc wi th in battery l imi t
o f the package. A l l the in te rconnect ions wi th o ther ear th ing systems o f the p lan t and wi th
exist in g system s shal l be und er scope o f t he Bidder .
Technical Specificati on: Electr ical Page 64 of 77
The Bidder shal l obtain the actu al soi l resist iv i ty of the plant a rea by carrying out soi l resist iv i ty
tests and design t he earth ing system accordingly.
Whi le designing the earth ing system, Bidder shal l note the fo l lowing faul t levels at 415 V bus
shall be 50 kA. Plant earthing system shall be designed such that overall earthing resistance isless than 1(One) Ohm w i thout in te rconnect ions.
The mater ia ls shal l be galvanized steel la id over the ground and mi ld steel bur ied inside the
ground/concre te .
Faul t c lear ing t ime for sizing of earth conduct ors and fo r calculat io ns of t he m aximum al low able
step and touch po tent ia l sha l l be taken 1 sec. M aximum a l low ab le temp era ture r ise fo r stee l
bo l ted jo in ts sha l l be taken as 3100C tak ing amb ient tem pera ture o f 50oC.
The eart h ing system shal l be general ly designed on th e basis of t he fo l low ing codes & stand ards:
• IS 3043 Code of pract ices for safety and standards
• IEEE 80 Guide f or safet y in AC substat ion gro un ding
• Ind ian Electr icity Rules
Enti re system shal l be earthed so that the values of the step and contact potentia ls in case of
faul ts are kept w i th in safe perm issib le l im i ts.
Parts of a l l e lectr ical equ ipm ent and m achin ery not int ended t o be al ive shal l have tw o separate
and dist inct earth connectio ns each to confo rm to t he st ip ulat ion of t he Indian Electr ic i ty Rules.In case o f HT system , E/ F cur rent w i l l be m ade to f low th ro ugh copper screen t ape prov ided over
inner sheathing. Screen wi l l be connected to earth bus at both ends. In case of LT the TN-S
system wi l l be fo l lowed, i .e. neutral bus of the switchgear shal l be connected to switchgear
ear th bu s and th en to DBs sha l l be th rou gh armour ing o f cab le .
B idder sha l l submi t the layout d rawings o f ear th ing network wi th suppor ted ca lcu la t ions fo r
approval of purchares/con sul tant . Taking approval of Electr ical inspecto r/ CEA and p rovid ing al l
inputs to them l ike data / drawings are under scope o f t he B idder .
The mater ia ls shal l be galvanized steel la id over the ground and mi ld steel bur ied inside the
ground/concre te .
Earth ing of SLDBs, power receptacles, etc shal l be connected with respective source LDBs
thro ugh armour ing o f cab les.
Earth ing conductors run on wal ls/f loors/cable and equipment structures etc. shal l be supported
at su i tab le in te rva ls and pa in ted w i th b lack ox ide pa in t .
The arm our o f cables and al l condui t s for cables shal l a lso be conn ected to the eart h ing ma ins. A
cont inuous earth str ip shal l run in each side of cable channel and in cable duct s/t ray rout e.
Technical Specificati on: Electr ical Page 69 of 77
The op erat ion o f th e W T SYSTEM plant shal l be m onit ored and con tro l led fr om the exist ing WT
contro l roo m s by m eans o f VDU opera tor in te r face on a m icroprocessor based p rogram mable
logic control ler (PLC). The system shal l be envisaged for the purpose of in i t ia l operat ion,
protect ion and inter lock, data acquisi t ion, close loop control , data archiving, etc for fu l lyautomatic operat ion. The system shal l be capable of monitor ing and displaying the status of
equipment, including the analog and dig i ta l s ignal d isplaying of status in the form of d iagram,
tren d bar chart, overview , logs, etc w i th t he help of CRT, keyboard, mo use and pr inters.
Necessary h ardwa re and soft w are l icense of the propo sed PLC shal l be p rovided
The pr efer red m ake of PLC shall be GE-FANUC mak e.
BELT SW AY SW ITCH
The bel t sway switch shal l be shal l be auto reset type and provided at both ends and at an
interval of 50 mtrs ( for conveyor length greater that 200 mtrs) on both sides of conveyors and
a lso b efore and a f te r be l t w e igh ing system on both sides. I t sha ll be o f au to reset type.
The bel t sway switch shal l be industr ia l heavy duty type housed in dust and vermin proof box
with degree of protect ion IP-54. The switch shal l be designed that conveyor does not come in
direct contact wi th the switches and mechanism shal l have strong rest spr ing to absorb high
impact o f loaded b e l t edge.
The sw itch elem ent shal l be sel f rest t ype and shal l have 2NO+2NC contacts each rated f or 10A,
240V AC. I t shal l be sui table for ambient temp. of 600C. Resett ing spr ing mechanism, bui l t in
terminal box, actuating ro l lers, ro l ler shafts, support ing frame, etc shal l be provided as per
requ iremen t. Belt sway swit ch shal l be J& N m ake.
PULL CHORD SW ITCH
Pul l chord sw itches shal l be auto r eset t ype indu str ia l heavy du ty enclosed in du st and verm in
proo f enclosure w ith d egree of p rote ct ion IP-65. They shal l be provided w ith fo l lowin g faci li t ies;
• Sw itch elem ent s shal l be 2NO+2NC each rat ed fo r 10A, 240V AC.
• Autom at ic lock ing ar rangement in the opera ted pos i t ion w i th m anua lly reset
• Snap act ion t ype fo r pos it i ve op era t ion o f contacts
• Num ber o f posi t ion shal l be 1-0-1
• Separate compar tm ent fo r bu i lt in te rm ina l box
• Suitable base plate Pul l rop e shal l be stranded galvanized steel w ire w i th at least 1 m m
th ick PVC cover and hav ing overal l d iameter o f 6m m to 7mm .
Pul l rope swi tch sha ll be p laced a t an in t e rva l o f 25 m tr o n bot h s ides o f conveyor w i th m in im umof on e pa i r fo r conveyor length less than 25 m tr .
Technical Specificati on: Electr ical Page 74 of 77
Al l the equ ipments sha l l be tested a t s i te to know the i r cond i t ion and to prove su i tab i l i ty fo r
requ i red per fo rm ance.
The test ind icated in fo l low ing pages shal l be condu cted aft er instal lat ion . Al l too ls, accessor ies
and requ i red inst ruments sha l l have to be ar ranged by contractor . Any o ther test wh ich iscons idered necessary by the manufacturer o f the equ ipment , contractor o r ment ioned in
com m ission ing m anual has to b e conducted at si te.
In add i t ion t o t ests on ind ividua l equ ipm ent , som e tests/checks are to be conducted / observed
from overal l system point of v iew. Such checks are highl ighted under miscel laneous tests but
th ese shal l not b e l im i ted t o as indicated and shall be f inal ized w ith consul tat ion o f cl ient b efore
charging of t he system .
The contractor shal l be responsible for sat isfactory working of complete integrated system and
guaranteed per fo rm ance.
Al l checks and tests shal l be condu cted in the p resence of cl ient ’s representat ive and test r esul ts
shal l be subm itted in six copies to cl ient and o ne copy to Electr ical Inspecto r. Test resul ts shal l
be f i l led in p roper Per fo rm a.
After clearance from Electr ical Inspector system/ equipment shal l be charged in step by step
m e t h o d .
Based on the t est resul ts clear cut observation shal l be ind icated b y test ing engineer w i th r egard
to su i tab i li ty fo r charg ing o f t he equ ipm ent o r reasons fo r no t charg ing are to be b rought by th e
contractor .
Trial Run Test
After t he successfu l test o f each equ ipment as per standard test p rocedure the ent i re contro l
system shal l be put on t r ia l run t est on actua l s ite cond i t ions and opera t ion o f the system.
Accep ta nce Test
The acceptance test on the system shal l be carr ied out by the suppl ier as per mutual ly agreed
test procedures to establ ish sat isfactor i ly funct ioning of the system as a whole and each
equ ipment as par t o f the system .
Site Tests
The t ests to b e carr ied out o n th e equip m ent at p re-com m issioning stage shal l include fo l low ing
Technical Specificati on: Electr ical Page 75 of 77
4. Testing and cal ibrat ion of a l l m eters
5 . Checking and cal ibrat ion of p rot ect ive re lays as per suppl ier 's com m issioning m anuals
6 . Check opera t ion o f contactors f rom loca l and rem ote po in ts
7 . Checking of int er lockings bet w een incom ers/bu s coupler and oth er feeders.
8 . Test t o p rove inter changeabi l i ty of s im i lar parts9 . Tests to prove cor rect opera t ion o f b reakers a t min imum and maximum speci f ied
contro l vo l tages
10 . Checking of earth ing conn ection fo r neut ral-earth bu s, cable arm our, location o f E/ F CT
etc. as per th e scheme .
11 . Check test, service and drawout posi t ion of a l l the breakers and operat ions of
m echanical f lag indicator and electr ical ind icat ion lamp s.
12 . Check fun ct ion ing of var ious elect. schem es like auto changeover signal l ing et c.
13 . Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and
betw een phases in o f f po si t ion
M O T O RS
1 . IR test o f s ta to r and ro to r w ind ings.
2 . Ensure th at checking/t est ing of associated sw itchboard , cables, re lays / m eter in ter locks
as ment ioned in re levant a re com ple ted.
3 . Check t ightness of cable connection
4. W ind ing resistance measurem ent o f sta tor and ro to r .
5 . Checking cont inu i ty o f w ind ing .
6 . Check t ightn ess of earth conne ctions.
7 . Check space heaters and carryou t heat ing of w inding ( i f required)
8 . Check direct ion of ro tat ion in d e-coup led cond i t ion dur ing kick star t
9 . M easure no load cur rent fo r a l l phases.
10 . M easurem ent o f t emp era ture o f body dur ing no load and load cond i t ions.
11 . Check fo r t r ipp ing o f motor f rom loca l / remote swi tches and f rom
electr ical / technological protect ion.
12 . Checking of vibrat ion
13 . Checking of no ise level
14 . Shaft vo l tage m easurem ent ( i f required)
15 . Tan de l ta test, i f required
16 . During load running, m easurem ent o f stat or and bear ing temp eratur es ( i f app l icable) for
every hal f an hou r interval t i l l satu rat ion com es.
17 . Checking t ightness of fo undat ion bol ts
18 . Check operat ion of speed switch ( i f ther e)
19 . Check cont inu i ty o f t emp . de tectors.
20 . Check al ignm ent , paral le l ing of shafts, level of lubr icat ing oi l etc. as per m anufactu rer 's
manua l
21 . Check for po lar isat ion index of stato r w inding, R10/ R1 by m oto r ised m egger (The value
should no t b e less than 2.0). R60/ R10 absorp t ion co-eff icient shal l not be less than 1.5.
TRANSFORM ER
1. IR test on each w ind ing to ground and betw een w ind ings.
Technical Specificati on: Conditions of Cont ract for Field Services Page 2 of 26
per ASM E Section IX. M akes of w elding consum ables shal l be subject to emp loyer ’s
approval .
3.0 SITE RUN M ISCELLAN EOU S PIPIN G
Sketches or d iagrams of the proposed routings of a l l p ip ing, not a lready indicated and
rout ed on t he shop drawings wh ich w ere rev iew ed by the Emp loyer , sha l l be subm i t ted
to the Employer for review, Employer 's acceptance of such si te rout ings shal l be
obt ained befor e th e pip ing is erected. Al l these si te run pip ing shal l be in stal led in such a
m anner as to pre sent an o rder ly and neat in stal lat ion. They shal l be located as to avo id
obstru ct ion o f access and passages. Valves, instrum ents or any o ther special i tem s shal l
be located convenient for operat ion by the operat ing personnel. Pipe runs shal l be
plum b or level except w here pi tch f or drainage is required. Pipe runs that ar e not paral le lto the bui ld ing structure, wal ls or column rows shal l be avoided. No miscel laneous pipe
sha l l be rou t ed and insta l led above or ad jacent to e lect r ica l equ ipm ent .
4.0 PIPIN G SUPPORTS
4 .1 Hangers, supports and anchors shal l be instal led as required to obtain a safe, re l iable
and complete pipe instal lat ion. Al l supports shal l be proper ly level led and anchored
w hen in stalled. The anchors shal l be so placed that ther m al expansion w i l l be absorbed
by bend s witho ut subject ing t he valves or equipm ent t o excessive stra ins.
4.2 The hanger assemb l ies shall no t be used for th e att achmen t of r igging to ho ist the pipe
into place. Other means shal l be used to securely hold the pipe in p lace t i l l the pipe
support is completely assembled and attached to the pipe and bui ld ing structures and
spr ing support is set to accommodate the pipe way. Al l temporary r igging shal l be
remo ved in such a way tha t the p ipe suppor t i s no t sub jected to any sudden load. A ll
p ip ing, having var iable spr ing t ype suppor ts, shal l be held securely in p lace by t emp orary
means dur ing the hydraul ic test of p ipe system. Constant support type spr ing hangers
used dur ing hydraul ic test shal l be pinned or b locked sol id dur ing the test. After
comple te insta l la t ion and insu la t ion o f the p ip ing and f i l ling o f the p ip ing w i th i ts norm al
operat ing medium, the pipe support spr ings shal l be adjusted to the cold posi t ions. I f
necessary, the spr ing suppo rt shal l be re-adjusted to the ho t po sit ion s after the l ine has
been p laced fo r serv ice a t i ts normal maximum opera t ing tempera ture cond i t ions.
Electr ic arc welding only shal l be used to weld al l p ipe supports to structural steel
m emb ers tha t fo rm par t o f t he bu i ld ing suppor t ing st ructure . The s t ructura l beams sha l l
not be heated m ore t han necessary dur ing w elding of suppo rts and such w elds shal l run
para lle l to the ax is o f t he span. A l l lugs or any o th er a t tachment s we lded to the p ip ing
Technical Specificati on: Conditions of Cont ract for Field Services Page 3 of 26
5.0 CODE REQU IREM ENTS
The erect ion requ i rement s and pro cedures to b e fo l lowed du r ing the insta lla t ion o f the
equipment shal l be in accordance with the re levant Indian Electr ic i ty Rules & Codes,
Indian Boi ler Regulat ions, ASM E codes and accepted good pract ices, th e Em ployer 's
Draw ings and oth er appl icable Indian recognised codes and law s and regulat ion s of the
Government o f Ind ia.
6. 0 ELECTRICAL SAFETY REGULATIO NS
6.1 In no circum stances w i l l th e Cont ractor int er fere with fuses and electr ical equipm ent
be long ing to the o t her Contractor o r Emp loyer .
6.2 Before the Con tracto r connects any electr ical appl iances to any plug or socket belonging
to the o ther Cont ractor o r Employer , he sha l l:
a ) Satisfy the Em ployer t hat t he appl iance is in good w orking condi t ion ;
b ) In fo rm the Emp loyer o f the m aximu m cur rent ra t ing , vo l tage and phases o f t he
appliances;
c) Obta in perm ission o f the Employer de ta i l ing th e socket to wh ich the app l iances
m ay be connected.
6 .3 No repa ir wo rk sha l l be car r ied out on any l i ve equ ipm ent . The equ ipment mu st bedeclared safe by the Employer and a permit to work issued before any work is carr ied
o u t .
6.4 The Cont ractor shal l em ploy the necessary num ber of qual i f ied, fu l l t im e electr ic ians to
m aintain his tem porary electr ical instal lat ion.
7.0 REM OVAL OF M ATERIAL
No m ater ia l b rought to t he Si te sha l l be remo ved f rom t he Si te by the Cont ractor and /or
h is Sub-Contractors wi thou t t he pr io r w r i t ten approva l o f the Em ployer .
8.0 INSPECTION, TESTING AN D IN SPECTION CERTIFICATES
The prov isions of the clause ent i t led Inspect ion, Testing and Inspection Cert i f icates given
in General Techn ical Requirem ent, shal l a lso be appl icable to t he erect ion po rt ion o f t he
W ork s. The Em ployer shall have the r ight t o re- inspect any equipm ent t hou gh previously
inspected and approved by h im a t t he Cont ractor ’s works, be fore and a f te r th e same are
erected at Si te. I f by the above inspection, the Employer re jects any equipment, the
Technical Specificati on: Conditions of Cont ract for Field Services Page 4 of 26
Contractor shal l make good for such reject ions ei ther by replacement or modif icat ion/
repairs as m ay be necessary to th e sat isfact ion of the Emp loyer. Such replacemen ts w i l l
a lso inc lude the rep lacements or re -execut ion o f such o f those works o f o therContractors and/or agencies, wh ich might have got damaged or a f fected by the
rep lacement s or re -wo rk done to the Contractor ’s work.
9.0 ACCESS TO SITE AN D W O RKS O N SITE
9.1 Sui table access to si te and perm ission to w ork at the Si te shal l be accorded to th e
Contractor by t he Employer in reasonab le t im e.
9 .2 In the execut ion o f the Works, no person o ther than the Contractor o r h is du ly appo in ted
representa t ive , Sub-Cont ractor and w orkm en, sha l l be a l low ed to do wo rk on the Si te ,except by th e special perm ission, in w r i t ing by t he Emp loyer or h is repr esentat ive.
10 .0 CON TRACTOR’S SITE OFFICE ESTABLISHM ENT
The Contractor shal l establ ish a Off ice at the Si te and keep posted an author ized
representa t ive fo r th e purpose o f the Contract . Any wr i t ten order o r inst ruct ion o f the
Employer or h is duly author ised representat ive, shal l be communicated to the said
author ised resident representat ive of the Contractor and the same shal l be deemed to
have been com m unicated t o th e Con tracto r at h is legal address.
11.0 CO-OPERATION W ITH OTHER CONTRACTORS
11.1 The Contractor shal l co-operate wi th a l l other Contractors or tradesmen of the
Employer , who may be per fo rming o ther works on beha l f o f the Employer and the
w orkm en who m ay be emp loyed by th e Emp loyer and do ing work in the v ic in i ty o f th e
works under the Contract. The Contractor shal l a lso arrange to perform his work as to
min imise , to the maximum extent poss ib le , in te r fe rence wi th the work o f o ther
Contracts and the i r workmen. Any in ju ry or damage tha t may be susta ined by the
employees o f the o ther Contractors and the Employer , due to the Contractor ’s work
sha l l p rompt ly be made good a t h is own expense. The Employer sha l l de termine the
reso lu t ion o f any d i f fe rence or conf l i ct tha t m ay ar ise betw een the Contractor and o ther
Contractors or be tw een the Cont ractor and th e wo rkmen o f the Em ployer in regard t o
the i r w ork. If t he w ork o f th e Cont ractor is de layed because o f t he any acts o f o m ission
of another Contractor, the Contractor shal l have no cla im against the Employer on that
account o ther than an extens ion o f t ime fo r com ple t ing h is works. Emp loyer sha l l have
ful l access to visit t he con tracto r ’s si te at an y t im e for inspection and survei l lance checks.
Technical Specificati on: Conditions of Cont ract for Field Services Page 5 of 26
11.2 The Emp loyer sha l l be not i f ied prom pt ly by the Contr actor o f any defects in th e o ther
Contractor ’s works that could affect the Contractor ’s Works. The Employer shal l
determine the correct ive measures i f any, required to rect i fy th is si tuat ion afterinspection of the works and such decisions by the Employer shal l be binding on the
Contractor .
12.0 DISCIPLINE OF W ORKM EN
The Cont ractor shal l adhere t o th e discip l inary procedure set by t he Emp loyer in respect
o f h is emp loyees and w orkm en a t Si te . The Em ployer sha l l be a t l iber ty to ob ject to the
presence o f any representa t ive or employee o f the Contractor a t the S i te , i f in the
opinion of the Employer such employee has mis-conducted himself or is incompetent,
negl igent or otherwise undesirable then the Contractor shal l remove such a personob jected to and prov ide in h is p lace a compet ent rep lacement .
13. 0 CONTRACTOR’S FIELD OPERATION
13.1 The Cont ractor shal l keep t he Em ployer info rm ed in advance regarding his f ie ld act iv i ty
plans and schedu les for carrying out each part of t he w ork s. Any review of such plan or
schedu le or m ethod o f w ork by t he Em ployer sha l l no t re l ieve the Contr actor o f any o f
his respo nsibi l i t ies tow ards the f ie ld act iv i t ies. Such reviews shal l a lso n ot be considered
as an assum pt ion of any r isk or l iabi l i ty b y the Emp loyer or any o f h is representa t ives and
no c la im o f t he Cont ractor w i l l be ent er ta ined b ecause o f the fa i lu re o r ine f f iciency o fany such plan or schedule or method of work reviewed. The Contractor shal l be sole ly
responsible for the safety, adequacy and eff ic iency of p lant and equipment and his
erect ion m ethods.
13.2 The Cont ractor shal l have the com plete responsibi l i ty for th e condi t ion s of the W ork-
Si te including the safety of a l l persons emplo yed by him or h is Sub-Con tracto r and al l the
proper t ies under h is custody dur ing the per fo rm ance o f the w ork. Th is requ i rement sha l l
app ly cont inuously t i ll the comple t ion o f the Contr act and sha ll no t be l imi ted to norm al
work ing hours. The construct ion rev iew by the Employer is no t in tended to inc lude
review of Contracto r ’s safety m easures in, on o r near th e Wo rk- Si te, and t heir adequacy
or o therw ise .
14 .0 PHO TOGRAPH S AN D PROGRESS REPORT
14.1 The Contractor shal l furnish three (3) pr ints each to the Employer of progress
pho tographs of t he w ork don e at Site. Pho tographs shal l be taken as and w hen indicated
by the Employer or h is representat ive. Photographs shal l be adequate in size and
Technical Specificati on: Conditions of Cont ract for Field Services Page 7 of 26
In add i t ion to a l l loca l law s and regu la t ions per ta in ing to t he emp loyment o f labour to b e
compl ied with by the Contractor pursuant to GCC, the Contractor wi l l be expected to
employ on the work only h is regular ski l led employees with exper ience of the part icularw ork. No f emale labour sha l l be emp loyed a f te r darkness. No p erson b e low the age o f
eighteen years shal l be emp loyed.
Al l travel l ing expenses including provisions of a l l necessary transport to and from Site,
lodging al lowances and other payments to the Contractor ’s employees shal l be the sole
responsibi li ty of th e Cont ractor.
The hours of w ork on the Site shal l be decided by t he Em ployer and t he Cont ractor shal l
adhere to i t . W ork ing hours wi ll norm al ly be e igh t (8 ) hours per day – M onday th rough
Saturday. Contractor ’s emp loyees shal l wear iden ti f icat ion badges wh i le on w ork at Site.
In case the Employer becomes l iable to pay any wages or dues to the labour or any
Government agency under any o f the prov isions o f the M in imum Wages Act , Wo rkm en
Compensation Act, Contact Labour Regulat ion Abol i t ion Act or any other law due to act
of om ission by t he Con tracto r, the Emp loyer m ay make such paym ents and shall recover
the same f rom the Contractor ’s paym ents.
18 .0 FACILITIES TO BE PROVID ED BY THE EM PLOYER
18.1 Space
The Contractor shal l advise the Employer wi th in th i r ty (30) days from the date ofacceptance o f the Not i f i ca t ion o f Award about h is exact requ i rement o f space fo r h is
off ice, storage area, pre-assembly and fabr icat ion areas, labour and staff colony area,
etc. The above r equirem ent shal l be review ed by th e Emp loyer and space as decided by
Emp loyer wi l l be a l lo t t ed to the Contractor fo r construct ion o f h is tempo rary st ructu res/
faci li t ies l ike of f ice, sto rage sheds, pre-assembly and f abr icat ion ar eas, labour and staff
colony, t o i lets, etc. for Cont ractor 's as wel l as his Sub-Cont ractor ’s u se.
18.2 Electricity
The Contractor sha l l submi t to the Employer wi th in th i r ty (30) days f rom the date o f
acceptance of the Noti f icat ion of Award, h is e lectr ical power requirements, i f any, to
al low the planning of the same by the Employer. The Contractor shal l be provided with
f ree supp ly o f e lect r ic ity fo r t he purpo ses o f t he Contract , on ly a t t w o locat ions in th e
Employer ’s Si te and at 415V vol tage level . The Contractor shal l make his own fur ther
d ist r ibu t ion ar rangement . A ll tem porary w i r ing mu st comply w i th loca l regu la t ions and
wi l l be subject to Employer ’s inspection and approval before connection to supply. The
free supp ly o f power wi l l no t be prov ided fo r the use in the labour and s ta f f co lony.
Power supply for labour and staff colony shal l be provided at one point and the
Technical Specificati on: Conditions of Cont ract for Field Services Page 8 of 26
Cont ractor shal l be charged at rates prevalent at t he si te. I l lum ination o f wagon t ipp ler
and t he conveyor area sha l l be th e scope o f t he t enderer .
1 8 . 3 W a t e rContractor shal l make al l arrangements himself for the supply of construct ion water as
w el l as po tab le wat er fo r labour and o ther personne l a t the w orks ite / co lony.
18.4 Communicat ion
The Employer wi l l extend the te lephone faci l i t ies, i f avai lable at Si te, for purposes of
Cont ract. The Cont ractor shal l be charged at actuals for such faci l it ies.
19 .0 FACILITIES TO BE PROVID ED BY THE CON TRACTOR
19.1 Cont ractor's site off ice Estab lishm ent
The Contractor shal l establ ish a si te off ice at the si te and keep posted an author ized
representa t ive fo r the pu rpose o f th e contract , pursuant to GCC.
19 .2 Too ls, ta ckles an d scaffold ings
The Contractor shal l provide al l the construct ion equipments, tools, tackles and
scaffo ld ings required for pre-assembly, instal lat ion, test ing, commissioning and
conducting Guarantee tests of the equipments covered under the Contract. He shal l
submi t a l i s t o f a l l such mater ia ls to the Employer be fore the commencement o f
preassemb ly at Si te. These too ls and tackles shal l not b e rem oved from th e Si te w i tho utthe wr i t ten permission of the Employer. The Contractor shal l arrange Dozer, Hydra,
Cranes, Trailer , etc. for t he p urpo se of fabr icat ion, erect ion and com m issioning.
19.3 Testing Equipme nt and Facilit ies:
The contracto r shal l provide th e necessary t est in g, equ ipm ent and faci li t ies.
19.4 Site labo rato ry for civil w orks:
Contractor sha ll p rov ide and main ta in a s i te labora tory fo r the test ing o f construct ion
m ater ial under the d i rect ion and genera l superv ision o f emp loyer .
19.5 First-aid
19.5.1 The Cont racto r shall pro vide n ecessary first-aid f acil i t ies fo r al l h is emp loyees,
representa t ives and workmen work ing a t the S i te . Enough number o f Contractor ’s
personnel shal l be t ra ined in adm inister ing f i rst-a id.
19.5.2 The Em ployer w i l l provide th e Con tracto r, in case of an y em ergency, the services of an
ambu lance fo r t ranspor ta t ion to the n earest ho sp i ta l .
Technical Specificati on: Conditions of Cont ract for Field Services Page 9 of 26
19.6 Cleanliness
19.6.1 The Contracto r shall be responsible for keeping the ent i re area al lott ed t o h im clean and
free fro m rubb ish, debr is etc. dur ing th e per iod of Cont ract. The Con tracto r shall emp loyenou gh num ber of special personnel to t ho roughly clean his w ork-area at least once in a
day. Al l such rubbish and scrap mater ia l shal l be stacked or d isposed in a place to be
ident i f ied by th e Emp loyer. M ater ia ls and stores shal l be so arranged to p erm it easy
c lean ing o f the area. In a reas where equ ipmen t m ight d r ip o i l and cause damage to the
f loor surface, a sui table protect ive cover of a f lame resistant, o i l proof sheet shal l be
prov ided to p ro tect the f loor f ro m such damage.
19.6.2 Simi lar ly the labour colony, the off ices and the residentia l areas of the Contractor ’s
emp loyees and w orkm en shal l be kept c lean and neat to the ent i re sa t isfact ion o f the
Employer. Proper sani tary arrangements shal l be provided by the Contractor, in the
w ork -areas, off ice and resident ia l areas of the Contracto r.
20 .0 LIN ES AN D GRADES
All the Works shal l be performed to the l ines, grades and elevations indicated on the
drawings. The Contractor shal l be responsible to locate and layout the Works. Basic
hor izont al and vert ical con trol po ints w i ll be establ ished and m arked by the Employer at
Si te at sui table points. These points shal l be used as datum for the works under the
Contract . The Contractor sha l l in fo rm the Employer we l l in advance o f the t imes and
p laces a t w h ich h e wishes to d o w ork in th e area a llo t ted to h im so tha t su i tab le da tum
points may be establ ished and checked by the Employer to enable the Contractor toproceed wi th h is w orks. Any w ork done w i thout be ing proper ly loca ted m ay be removed
and/ or d ismant led by t he Emp loyer a t Cont ractor ’s expense.
21 .0 FIRE PROTECTION
21.1 The work procedu res that are to be used dur ing the erect ion shal l be tho se which
minimise f i re hazards to the extent pract icable. Combustib le mater ia ls, combustib le
w aste and rubbish shal l be col lected and r emo ved from th e Si te at least once each day.
Fuels, o i ls and volat i le or f lammable mater ia ls shal l be stored away from the
construct ion and equipment and mater ia ls storage areas in safe containers. Untreated
canvas, paper, p last ic or ot her f lamm able f lexib le mat er ia ls shal l not at a l l b e used at Si te
for any o ther pu rpose unless ot herw ise speci f ied. If any such m ater ia ls are received w ith
the equ ipment a t the S i te , the same sha l l be removed and rep laced wi th acceptab le
m ater ial be fore m oving in to t he construct ion or s to rage area.
21.2 Simi lar ly corrugated paper fabr icated cartons etc. wi l l not be permitted in the
construct ion area eith er for storage or for hand l ing of mat er ia ls. Al l such m ater ia ls used
sha l l be o f wat er p roof and f lame resistan t type. A l l the o ther mat er ials such as w ork ing
Technical Specificati on: Conditions of Cont ract for Field Services Page 11 of 26
devices requ i red dur ing s tar t -up and opera t ion o f the equ ipment systems wh ich are
erected b y him . The Contracto r shall a lso be respon sible fo r f lushing and in i t ia l f i l l ing of
al l the oi l and lub r icants required fo r th e equipm ent fu rnished and instal led by him , so asto make such equipment ready for operat ion. The Contractor shal l be responsible for
supplying such f lushing oi l and ot her lub r icants.
25.0 PRE-COM M ISSIONING AND COM M ISSIONING ACTIVITIES
(a) GENERAL
The Contractor upon complet ion of instal lat ion of equipments and systems, shal l
conduct pre-commissioning and commissioning act iv i t ies, to make the
equipment/systems ready for safe, re l iable and eff ic ient operat ion on sustained basis.Al l pre-com m issioning/ com m issioning act iv i t ies considered essent ia l for such readiness
of the equ ipment /systems inc lud ing those mutua l ly agreed and inc luded in the
Contractor ’s qual i ty assurance programme as wel l as those indicated in clauses
elsew here in th e technical specif icat ions shall be perfo rm ed by th e cont ractor.
(b) The pre-com m issioning and com m issioning act iv i t ies including Guarant ee tests, checks
and t r ia l opera t ions o f t he equ ipm ent / system s fu rn ished and insta l led by the cont ractor
shall be t he re spon sibi l i ty o f t he Contractor as det ai led in re levant clauses in Technical
Speci f icat ion. The Contractor shal l provide, in addi t ion, test instruments, cal ibrat ing
devices etc. and labour r equired fo r successful perform ance of t hese op erat ions. If i t isan t ic ipa ted tha t the above test may pro long fo r a long t ime, the Contractor ’s workm en
requ ired for t he above test shal l a lways be pr esent at si te du r ing such operat ions.
(c) The fo l low ing act iv i t ies shal l be carr ied out by the cont ractor, pr ior to schedu le date of
comm iss ion ing o f t he equ ipm ent / systems insta l led by h im.
( i ) The cont ractor shal l fu rnish the organizat ion chart o f h is operat ion and
commiss ion ing eng ineers fo r the acceptance o f employer . Adequate number o f
operat ion and commissioning engineers shal l be deployed by the contractor to
e f fect ively meet the requ i rement o f r ound the c lock opera t ion in sh i f ts a lso , t i l l the
p lan t is taken over by the em ployer .
( i i) The cont ractor shal l subm it the bio-data cont ain ing the detai ls of exper ience of h is
opera t ion and comm ission ing eng ineers fo r the acceptance o f employer .
( i i i ) The contractor shal l furnish the deployment schedule of h is operat ion and
com m issioning engineers for th e acceptance of th e em ployer.
( iv) Apart from above, contractor shal l ensure deployment of suff ic ient ski l led/semi-
ski l led/ un ski l led m anpow er dur ing pre-com m issioning and comm issioning act iv it ies.
Technical Specificati on: Conditions of Cont ract for Field Services Page 14 of 26
(d ) A l l equ ipm ent sha ll be hand led w i th care to p revent any damage. No bare wi re
ropes, sl ings, e tc . sha l l be used fo r un load ing and/ or hand l ing o f the equ ipment w i thoutthe spec if ic wr i t t en p erm ission o f the Employer . The equ ipm ent sto r ed sha ll be p roper ly
pro t ected to prevent damage to the equ ipm ent . The equ ipment f rom the s tore sha l l be
moved to the actua l loca t ion a t the appropr ia te t ime so as to avo id damage o f such
equ ipment a t Si te .
(e) Al l e lectr ical panels, con trols gear, mo to rs and such other devices shal l be proper ly
dr ied b y heating befo re th ey are instal led and energised. M ot or bear ings, sl ip r ings,
commutators and other exposed parts shal l be protected against moisture ingress and
corrosion dur ing storage and per iodical ly inspected. Heavy rotat ing parts in assembled
cond i t ions sha l l be per iod ical ly ro ta ted to prevent cor ro sion du e t o pro longed s torage.
( f) The Cont ractor shal l ensure tha t a l l th e packing m ater ia ls and protect ion devices
used fo r the var ious equ ipments dur ing t rans i t and s torage are removed before the
equ ipment a re insta l led .
(g) The consum ables and oth er supp l ies l ikely to det er iorate due to storage must be
thorough ly pro tected and s tored in a su i tab le manner to prevent damage or
deter io ra t ion in qua l ity by s torage.
(h) A l l the m ater ia ls s to red in th e open or dusty locat ion m ust be covered w i th su i tab lew eatherproof and f lameproof cover ing m ater ia l wh erever app l icab le .
( i ) I f th e mat er ia ls belonging to th e Con tracto r are sto red in areas oth er than tho se
earmarked fo r h im, the Employer wi l l have the r igh t to ge t i t moved to the area
earmarked fo r the Cont ractor a t t he Cont ractor ’s cost .
( j ) The Con tracto r shal l be respon sible for making sui table indoo r stor age facil i t ies to
store al l equipm ent w hich require indoor storage. Norma l ly, a l l the electr ical equip m ent s
such as motors, control gear, exci ters and consumables l ike electrodes, lubr icants etc.
shal l be stored in the closed storage space . The Employer, in addi t ion, may direct the
Contractor to move cer ta in o ther mater ia ls , wh ich in h is op in ion wi l l requ i re indoor
storage, to indo or sto rage areas w hich the Con tracto r shal l str ict ly com ply wi t h.
29.0 CONSTRUCTION M ANAGEM ENT
(a) The f ie ld act iv it ies of th e Con tracto rs w orking at Si te, wi l l be coordinat ed by the
Em ployer and the Emp loyer decision shal l be f inal in resolving any disput es or con fl icts
between the Contractor and o ther Contractors and t radesmen o f the Employer
Technical Specificati on: Conditions of Cont ract for Field Services Page 15 of 26
regarding schedul ing and co- ordination of w ork. Such d ecision by the Emp loyer shall not
be a cause fo r ext ra compensat ion or extens ion o f t ime fo r th e Cont ractor .
(b) The Emp loyer shal l hold w eekly m eetings of a l l th e Cont ractors wor king at Si te, at a
t ime and place to be designated by the Employer. The Contractor shal l attend such
meetings and take notes of d iscussions dur ing the meeting and the decisions of the
Em ployer and shal l str ict ly adhere to th ose decisions in perfor m ing his W orks. In addi t io n
to the above weekly meet ing , the Employer may ca l l fo r o ther meet ing e i ther wi th
individual Contractors or wi th selected number of Contractors and in such a case the
Cont ractor i f cal led, w i l l a lso att end such m eetings.
(c) Tim e is th e essence of the Contract and th e Cont ractor shall be respon sible for
performance of h is works in accordance with the speci f ied construct ion schedule. I f atany t ime, t he Contracto r is fa l ling behind the schedu le, he shal l take necessary act ion t o
make good fo r such de lays by increas ing h is work fo rce or by work ing over t ime or
o therwise acce lera te the progress o f the work to comply wi th the schedu le and sha l l
communicate such act ions in wr i t ing to the Employer, sat isfying that h is act ion wi l l
compensate for the delay. The Contractor shal l not be al lowed any extra compensation
for such act ion.
(d) The Em ployer shall how ever not be respon sible for provision of addi t ion al labour
and/or mater ia ls o r supp ly or any o ther serv ices to the Contractor except fo r the
coord ina t ion w ork w i th o ther Contr actors , i f necessary.
30 .0 FIELD OFFICE RECORD S
The Contractor shal l maintain at h is Si te Off ice up-to- date copies of a l l drawings,
speci f icat ions and other Contract Documents and any other supplementary data
complete wi th a l l the latest revisions thereto. The Contractor shal l a lso maintain in
add i t ion the cont inuous record o f a l l changes to the above Contract Documents,
drawings, speci f icat ions, supplementary data, etc. effected at the f ie ld and on
com plet ion o f h is tota l assignm ent u nder t he Con tract shal l incorpo rate al l such changes
on the drawings and other Engineer ing data to indicate as instal led condi t ions of the
equipment furnished and erected under the Contract. Such drawings and Engineer ing
data sha ll be subm i t ted t o t he Em ployer in requ isi te num ber o f cop ies.
31.0 CON TRACTOR’S M ATERIALS BROUGHT ON TO SITE
(a) The Cont ractor shal l br ing to Si te a l l equ ipm ent, com pon ent s, part s, m ater ia ls,
inc lud ing construct ion equ ipment , too ls and tack les fo r the pu rpose o f the Wo rks under
in t im at ion to the Employer . A ll such goods sha l l, f rom the t ime o f th e i r be ing brought
Technical Specificati on: Conditions of Cont ract for Field Services Page 16 of 26
vest in t he Emp loyer , bu t may be used fo r th e purpose o f th e W orks on ly and sha ll no t
on any account be removed or taken away by the Contractor wi thout the wr i t ten
permission of the Employer. The Contractor shal l nevertheless be sole ly l iable andresponsib le fo r any loss or destruct ion t hereof and dam age th ere to .
(b) The Em ployer shal l have a lien on such goods for any sum or sum s which may at any
t im e be due or o w ing to h im b y the Contractor , under , in respect o f o r by reasons o f th e
Contract. After g iving a f i f teen (15) days notice in wr i t ing of h is intention to do so, the
Em ployer shal l be at l iber ty t o sel l and dispo se off any such goods, in such m anner as he
sha l l th ink f i t inc lud ing pub l ic auct ion or p r iva te t rea ty and t o app ly the proceeds in or
to wa rds the sat isfact ion o f such sum or sum s due as aforesaid.
(c) A f te r the comple t ion o f the Wo rks, the Contractor sha l l remo ve f rom th e Si te underthe d i rect ion o f the Employer the mat er ia ls such as construct ion equ ipment , e rect ion
tools and tackles, scaffo ld ing etc. wi th the wr i t ten permission of the Employer. I f the
Cont ractor fa i ls to remo ve such m ater ia ls, wi th in f i f teen (15) days of issue of a not ice by
the Employer to do so then the Employer shal l have the l iberty to d ispose off such
mater ia ls as detai led under as speci f ied at clause no 31 (b) above and credi t the
proceeds there to to the account o f t he Contr actor .
32 .0 PROTECTIO N OF PROPERTY AN D CON TRACTOR’SLIABILITY
(a) The Cont ractor shal l be respon sible for any damage resul t ing from his operat ions.He shal l a lso be responsible for protect ion of a l l persons including members of publ ic
and employees o f the Employer and the employees o f o ther Contractors and Sub-
Contractors and al l publ ic and pr ivate property including structures, bui ld ing, other
p lan ts and equ ipment s and u t i l it ies ei ther above or b e low t he ground.
(b) The Cont ractor w i l l ensure provision of n ecessary safety equipm ent such as barr iers,
sign - boards, warn ing l ight s and alarms, etc. to p rovide adequate pro tect ion to p ersons
and property. The Contractor shal l be responsible to g ive reasonable notice to the
Employer and the Employers o f pub l ic o r p r iva te proper ty and u t i l i t ies when such
proper ty and u t i l i t ies are l i ke ly to ge t d amaged o r in ju red dur ing the p er fo rmance o f h is
Works and shal l make al l necessary arrangements wi th such Employers, re lated to
remo va l and/ or rep lacement o r p ro tect ion o f such prop er ty and u t i l it ies .
33.0 PAINTING
All exposed metal parts of the equipment including pip ings, structure ra i l ings, etc.
w herever appl icable, after instal lat ion unless oth erw ise surf ace protect ed, shal l be f i rst
pa in ted w i th a t least t w o coats o f su i tab le pr imer w h ich m atches the shop pr im er pa in t
Technical Specificati on: Conditions of Cont ract for Field Services Page 17 of 26
used, after th roughly cleaning al l such part s of a l l d i r t , rust, scales, greases, o i ls and o ther
foreign mater ia ls by wire brushing, scraping or sand blast ing and the same being
inspected and approved by the Employer for paint ing. Afterwards, the above parts shal lbe f in ished painted with three coats of a l lowed resin machinery enamel paints. The
minimum thickness of paint f i lm shal l not be less than 100 microns. The qual i ty of the
f in ish paint shal l be as per the standards of Bureau of Indian Standards (BIS) or
equ iva len t and t o be o f th e co lour as approved by t he Emp loyer .
34.0 INSURANCE
34.1 In addi t ion to th e condi t ion s covered under the Clause enti t led “ Insurance” in Section
General Condit ions of Contract (GCC), the fo l lowing provisions wi l l a lso apply to the
por t ion o f works to be done beyond the Contractor ’s own or h is Sub-Contractor ’sm anufactur ing W orks.
34.2 W orkme n’s Com pensat ion Insurance
This insurance shal l protect the Contractor against a l l c la ims appl icable under the
W orkm en’s Com pensation Act, 1948 (Governm ent of Ind ia). This pol icy shal l a lso cover
the Contractor against cla ims for in jury, d isabi l i ty d isease or death of h is or h is Sub-
Contractor ’s employees, wh ich fo r any reason are not covered under the Workmen’s
Com pensation Act, 1948. The l iabi l i t ies shal l not be less than the f o l low ing:
W orkm en's Com pensation - As per Statu to ry ProvisionsEm ployee's L iabi l i ty - As p er Statuto ry Provisions
Property Damage: Rs.100,000 for each occurr ence
34.3 Com preh ensive Genera l Liabil ity Insuran ce
34.3.1 The insurance shal l protect the Contractor against a l l c la ims ar is ing from in jur ies,
d isab i li t ies, d isease or death o f m embers o f pu b l ic o r damage to proper ty o f o th ers, due
to any act or omission on the part of the Contractor, h is agents, h is employees, h is
representat ives and Sub-Contractors or from r iots, str ikes and civi l commotion. This
insurance shal l a lso cover a l l the l iabi l i t ies of the Contractor ar is ing out of the Clause
ent i t led “ Defence of Sui ts” in Section General Cond it ion s of Con tract (GCC).
34.3.2 The hazards to be covered w i ll perta in t o a l l th e W orks and areas where th e Cont ractor,
h is Sub-Cont ractors, h is agents and h is emp loyees have to p erform w ork pu rsuant to the
Contract.
34.4 The above are only i llustrat ive l ist o f insurance covers nor m al ly required and i t w i l l be
th e responsibi l i ty of th e Con tracto r to m aintain al l necessary insurance coverage to th e
Technical Specificati on: Conditions of Cont ract for Field Services Page 18 of 26
extent both in t ime and amount to take care of a l l h is l iabi l i t ies ei ther d irect or indirect,
in pursuance of the Cont ract.
35.0 UN FAVOU RABLE W ORKING CON DITIONS
The Contractor shal l confine al l h is f ie ld operat ions to those works which can be
per formed wi thout sub ject ing the equ ipment and mater ia ls to adverse e f fects dur ing
inc lement w eather cond i t ions, l ike m onsoon, s to rm s, e tc . and d ur ing o ther un favourab le
construct ion condi t ions. No f ie ld act iv i t ies shal l be performed by the Contractor under
condi t ions wh ich m ight ad versely affect t he qual i ty and eff ic iency thereof, un less special
precautions or measures are taken by the Contractor in a proper and satisfactory
m anner in the per fo rm ance o f such W orks and w i th th e concur rence o f the Employer .
Such unfavourable construct ion condi t ions wi l l in no way rel ieve the Contractor of h isresponsib i l ity t o p er fo rm the Wo rks as per t he schedu le .
36.0 PROTECTION OF M ON UM ENTS AN D REFERENCE POIN TS
The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc.
w h ich he may com e across dur ing the course o f per fo rm ance o f h is Wo rks e ither d ur ing
excavation or e lsewhere, are proper ly protected and handed over to the Employer.
Simi lar ly th e Con tracto r shall ensure that th e bench m arks, reference po ints, etc., wh ich
are marked e i ther w i th th e he lp o f Emp loyer o r by the Employer sha l l no t be d istu rbed in
any way dur ing the per fo rmance o f h is Works. I f , any work is to be pre formed wh ichdisturb such reference, the sam e shal l be don e only after t hese are transferred t o ot her
sui table locations under the direct ion of the Employer. The Contractor shal l provide al l
necessary m ater ia ls and assistance fo r such r elocation o f re ference poin ts etc.
37.0 W ORK & SAFETY REGULATIONS
37.1 The Con tracto r shal l ensure proper safety of a ll th e wo rkm en, mater ia ls, p lant and
equ ipments be long ing to h im or to Employer o r to o thers , work ing a t the S i te . The
Contractor shal l a lso be responsible for provision of a l l safety notices and safety
equ ipment requ i red both by th e re levant leg is la t ion and t he Emp loyer as he m ay deem
necessary.
37.2 Al l equipment used in construct ion and erect ion by Contractor shal l meet
Indian/International Standards and where such standards do not exist, the Contractor
shal l ensure these to be absolutely safe. Al l equipments shal l be str ict ly operated and
m ain ta ined by t he Contractor in accordance w i th m anufacturer ’s opera t ion M anua l and
safet y instruct ion s and as per Guidel ines/Rules of Em ployer in t h is regard.
Technical Specificati on: Conditions of Cont ract for Field Services Page 19 of 26
37.3 Per iodical Examinatio ns and al l tests for a l l l i f t ing/ ho ist ing equipm ent & tackles shal l be
carr ied-out in accordance with the re levant provisions of Factor ies Act 1948, Indian
Electr ic ity Act 1910 and associated Law s/Rules in fo rce from t im e to t im e. A register ofsuch examinat ions and tests sha l l be prop er ly main ta ined by t he Contractor and w i ll be
prompt ly p roduced as and when des i red by Employer o r by the person author ised by
h i m .
37.4 The Cont ractor shall pro vide sui tab le safety equipme nt of p rescr ibed standard t o a l l
emp loyees and w orkm en accord ing to the need, as may be d i rected by Employer wh o
wi l l a lso have r ight to examine these safety equipments to determine their sui tabi l i ty,
re l iabi l ity, acceptabi l i ty and adaptabi l i ty.
37.5 The Cont ractor shall pro vide safe wo rking condi t ion s to a l l w orkm en and emp loyees atthe Site including safe means of access, rai l ings, stairs, ladders, scaffoldings etc. The
scaffo ld ings shal l be erected under the control and supervision of an exper ienced and
com peten t p erson. For erect ion, good and standa rd qual i ty of m ater ia l only shal l be used
by th e Cont ractor .
37.6 The Cont ractor shal l not inter fere or d isturb electr ic fuses, wir ing and oth er e lectr ical
equ ipment be long ing to the Employer o r o ther Contractors under any c i rcumstances,
w hat soever, unless expressly perm itted in w r i t ing by th e Em ployer to handle such fuses,
w i r ing or e lect r ica l equ ipment .
37 .7 No e lect r ic cab le in use by the Contractor /Employer wi l l be d istu rb ed w i thout p r io r
perm ission . No w e ight o f any d escr ip t ion w i l l be im posed on any cab le and no ladder or
simi la r equ ipment w i ll rest against o r a t t ached t o i t .
37.8 The Cont ractors shal l emp loy necessary num ber of q ual i f ied, fu l l t im e Electr ic ians/
Electr ical Sup ervisors t o ma intain h is tem porary electr ical instal lat ions.
37.9 In case any accident occurs dur ing the constru ct ion/ erect ion o r oth er associated
act iv i t ies under taken by the Contractor thereby caus ing any minor o r major o r fa ta l
in jury to h is employees due to any reason, whatsoever, i t shal l be the responsibi l i ty of
the Contractor to p ro mp t ly in fo rm the sam e to th e Emp loyer in p rescr ibed fo rm and a lso
to al l the autho r i t ies envisaged und er the app l icable law s.
37.10 The Em ployer shal l have th e r ight at h is sole discret ion to stop th e wo rk, if in h is opinion
th e wo rk is being carr ied out in such a way that i t m ay cause accident s and endanger th e
safet y of th e persons and /o r prop erty, and/ or equ ipmen ts. In such cases, the Contractor
shall be inform ed in w r i t ing about the nat ure of hazards and possible in jur y/ accident and
he sha l l comply to remove shor tcomings prompt ly . The Contractor a f te r s topp ing the
Technical Specificati on: Conditions of Cont ract for Field Services Page 20 of 26
speci f ic work can, i f fe l t necessary appeal against the order of stoppage of work to the
Emp loyer wi th in 3 days o f such stoppage o f w ork and d ec is ion o f t he Employer in th is
respect shal l be conclusive and binding on t he Contractor.
37 .11 The Contractor sha l l no t be ent i t led fo r any damages/ compensat ion fo r s toppage o f
w ork du e to sa fe ty reasons as prov ided above and the per iod o f such stoppage o f wo rk
w i ll no t be taken as an extens ion o f t ime fo r comp le t ion o f t he fac il it ies.
38.0 FOUNDATION DRESSING & GROUTING FOR EQU IPM ENT/ EQU IPM ENT BASES
38.1 The surfaces of foun dation s shal l be dressed to br ing th e to p surface of th e foundat ions
to the requ i red leve l , p r io r to p lacement o f equ ipment /equ ipment bases on the
foundat ions.
38.2 Al l th e equipm ent / eq uipm ent bases, shal l be grout ed and f in ished as per th ese
specif icat ions un less o therw ise recomm ended by the equ ipment manu facturer .
38.3 The concrete foun dation surfaces shal l be prop er ly prepar ed by chippin g, gr inding as
requ i red to br ing the top o f such foundat ion to the requ i red leve l , to p rov ide the
necessary roughn ess for bon dage and to assure eno ugh bear ing strength .
38.4 Grout
The grout shal l be high strength grout having a minimum character ist ic compressivestrength o f 60 N/ m m 2 at 28 days. The grout shal l be chlor id e - free, cem ent based, free
f lowing, non- metal l ic grout. The Grout shal l have good f lowabi l i ty even at very low
water/ grout powder rat io. The Grout shal l have character ist ics of control led expansion
to b e able to occupy i ts or ig inal volume t o f i l l the voids and to com pensate for shr inkage.
Grout shal l be of pre-mix var iety so that only water needs to be added before use. The
mix ing o f the Grout sha l l conform to the recommendat ions o f the manufacturer o f the
Grout .
38.5 Finishing of the Edges of the Grout
The poured grout shou ld be a l lowed to stand und isturb ed unt i l it i s w e l l se t . Imm edia te ly
thereaf te r , the dam sha l l be rem oved and grout w h ich extends beyond the edges o f t he
structu ral or equipm ent base plates shal l be cut of f , f lushed and re m oved. The edges of
the grout sha l l then b e po in ted and f in ished w i th 1 :2 cement m or tar p ressed f i rm ly to
bond w i th the body o f the g rou t and smoo thened w i th a too l to p resen t a smoo th
vert ical surface. The w ork shal l be don e in a clean and scienti f ic m anner and the adjacent
f loo r spaces, exposed edges of th e found ations, and structural steel and equipm ent b ase
plates shal l be tho rou ghly cleaned of any spi l lage of the grou t.
Technical Specificati on: Conditions of Cont ract for Field Services Page 22 of 26
operat ion do n ot suff er for w ant o f com m issioning spares. Al l comm issioning spares shal l
be deemed t o be inc luded in the scope o f t he Contract a t no ext ra cost to t he Emp loyer .
42.2 These spare wi l l be received and sto red by the Cont ractor at least 3 m ont hs pr io r to the
schedu le date o f commencement o f in i t ia l opera t ion o f the respect ive equ ipment and
uti l ised as and when required. The unuti l ised spares and replaced parts, i f any, at the
end o f successfu l comp le t ion o f guarantee tests sha l l be t he p roper ty o f the Contractor
and he w i ll be a l low ed to take these par ts back at h is ow n cost w i th t he perm ission o f
Employer. Employer wi l l be informed of the l ist of commissioning spares brought to si te
by th e contractor be fore br ing ing the same to t he s ite .
43.0 CABLING
43.1 Al l cables shal l be suppo rted b y conduit s or cable tray run in a ir or in cable channels.
These shal l be instal led in exposed run s paral le l or perp endicular to d om inant surfaces
wi th r igh t ang le tu rn made o f symmetr ica l bends or f i t t ings. When cab les are run on
cab le t rays, they sha ll be c lamped a t a m in imum in tervals o f 2000mm or o therw ise as
d i rected by th e Emp loyer .
43.2 Each cable, w het her pow er or cont rol , shal l be provided w ith a m etal l ic or p last ic tag of
an approved type, bear ing a cable reference number indicated in the cable and conduit
l ist (p repared by the Contractor ) , a t every 5 m eter run o r par t th ereof and a t bo th ends
of t he cable adjacent t o th e term inat ions. Cable rout ing is to b e done in such a w ay thatcables are accessible fo r any m aintenance and for easy ident i f icat ion.
43.3 Sharp bend ing and kinking of cables shall be avoided. The m inimu m radi i fo r PVC
insul ted cables 1100 V grade shal l be 15 D w here D is the overal l d iam eter o f th e cable.
Instal lat ion of other cables l ike high vol tage, coaxial , screened, compensating, mineral
insulated shal l be in accordance wit h th e cable manuf acturer ’s recom m endations.
43.4 In each cab le run some extra length sha ll be kept a t a su i tab le po in t to enab le one or tw o
stra igh t th r ough jo in ts to be m ade, shou ld t he cab le deve lop fau l t a t a la te r da te .
43.5 Cont rol cable term ination s shal l be m ade in accordance w ith w ir ing diagrams, using
ident i fy ing codes subject t o th e Em ployer ’s approval . M ult icore contro l cable jackets
shal l be removed as required to tra in and terminate the conductors. The cable jacket
shal l be left on the cable, as far as possib le, to the point of the f i rst conductor branch.
The insulated conductors from which the jacket is removed shal l be neatly twined in
bundles and terminated. The bundles shal l be f i rmly but not t ight ly t ied ut i l iz ing plast ic
or ny lon t ies or speci f ical ly treat ed fungus prot ected cord m ade for th is pu rpose. Cont rol
cable condu cto r insulat ion shal l be securely and evenly cut.
Technical Specificati on: Conditions of Cont ract for Field Services Page 25 of 26
and t o prov ide sui tab le packaging to perm it safe handl ing dur ing transit and at th e job
site.
(i ) Electr ical equipment, control and instrumentat ion shal l be protected against moistureand water damage. Al l external gasket surfaces and f lange faces, coupl ings, motor
pump shafts, bear ing and l ike i tems shal l be thoroughly cleaned and coated with rust
prevent ive compound as spec if ied above and pro tected w i th su i tab le woo d, met a l o r
o th er substant ia l type cover ing to ensure th e i r fu l l p ro tect ion .
(j ) Equipment having anti fr ict ion or sleeve bear ings shal l be protected by weather t ight
enclosures.
(k ) Coated surfaces shal l be pro tected against im pact, abrasion, d iscolourat ion and ot her
dam age. Surf aces w hich are dam aged shal l be repaired.
(l ) All exposed threaded parts shal l be greased and protected with metal l ic or other
substantia l type protectors. Al l female threaded openings shal l be closed with forgedsteel p lugs. A ll p ip ings, tub ing , and condu i t equ ipm ent and o th er equ ipm ent open ings
shal l be sealed with metal l ic or other rough usage covers and tapped to seal the
in ter io r o f t he equ ipment p ip ing, tub ing , o r condu i t .
(m ) Prov isions sha l l be m ade to ensure tha t wat er does not en t er any equ ipment dur ing
sh ipm ent o r in s to rage a t th e p lan t si te .
(n ) Returnable containers and special shipping devices shal l be returned by the
m anufactur er 's f ie ld represent at ive at the Contractor 's expense.
(o ) W hi le packag ing th e mat er ial , care sha l l be t aken f o r th e l imi ta t ion f rom the po in t o f
view of availabi l ity o f ra i lw ay w agon sizes in Ind ia.
44.3 Equipme nt Insta l la t ion
(a.) Genera l Requiremen ts
The Contractor shal l furnish al l construct ion mater ia ls, tools and equipment and shal l
per fo rm a l l work requ i red fo r comple te insta l la t ion o f a l l contro l and inst rument
equipment furnished under th is speci f icat ion. Contractor shal l prepare detai led
instal lat ion drawings for each equipment furnished under th is speci f icat ion for
Em ployer 's approval . Instal lat ion o f a l l equip men t/ system s furn ished by t h is speci f icat ion
shall be as per Emp loyer 's approval . Erect ion pro cedures not specif ied herein shal l be in
accordance wi th the recommendat ions o f the equ ipment manufacturers . The
procedures shal l be acceptable to the Employer. The Contractor shal l coordinate his
w ork w i th o th er supp l ie rs w here th e i r ins t ruments and dev ices are to be insta l led under
specifications.
(b.) Insta l la t ion M ater ia ls
All mater ia ls required for instal lat ion, test ing and commissioning of the equipment shal l
Technical Specificati on: Conditions of Cont ract for Field Services Page 26 of 26
(c.) Regulatory Requireme nts
All instal lat ion pr ocedures shal l confi r m w ith t he accepted good engineer ing pract ice andw ith al l appl icable govern m ental laws, regulat ion s and codes.
(d.) Cleaning
All equipment shal l be cleaned of a l l sand, d ir t and other foreign mater ia ls immediately
a f te r rem ova l f rom storage and before th e equ ipment is b rou ght to insta l la t ion s ite .
(e.) Equipment Assembly
Equipment instal led under these speci f icat ions shal l be assembled i f shipped
unassembled. The equipment shal l be dismantled and reassembled as required to
perfo rm the instal lat ion and com m i ssioning w ork d escr ibed in t hese speci f icat ions.
(f.) Defects
All defects in erect ion shal l be corrected to the sat isfact ion of the Employer and the
Project M anager. The dismant l ing and reassem bly of Con tracto r furnished equipm ent t o
rem ove defect ive parts, replace parts, or m ake adjustm ents shall be included as a part o f
the wo rk under t hese spec if ica t ions. The rem ova l o f contro l and inst rum ent equ ipment
in order to a l low bench cal ibrat ion, i f required, and the re- instal lat ion of the said
equ ipment a f te r ca l ib ra t ion sha l l a lso be inc luded as a par t o f the work under these
specifications.
45.0 DEVIATIONS DISPOSITIONIN G:
Any dev ia t ion to the contract and employer approved documents sha l l be proper ly
recorded in the format prescr ibed by NALCO. Al the deviat ions shal l be bought to the
know ledge of em ployer ’s represent at ive for sui table disposit ion ing.
46.0 NO N-DESTRUCTIVE TESTING ( ND T):
The contracto r shal l record resul ts of NDTs carr ied out at si te in th e form at acceptable to
emp loyer . Al l the rad iographs & i ts repor t du ly s igned & cor re la ted t o t he job sha ll be
handed over to t he em ployer . Sensit iv i ty o f a l l the t est equ ipment sha l l be com pat ib le to
the job & acceptance norm s agreed.
47. 0 TESTIN G EQU IPM ENT & FACILITIES:
Cont ractor shal l pro vide the t est in g equipm ent and faci l it ies necessary to carry out tests
order that the pr ime coat is r ig id ly anchored to the virg in metal surface. The surface preparat ion
shal l conform to p ictor ia l represent at ion of surface qual i ty grade of DIN 55928 (Part 4) or BS 4232
or IS 1477 - 1971 ( Part I ) . Any grease, o i l , dust or foreign m att er depo si ted o n t he surface after
prepara t ion sha l l be removed and care taken tha t the sur face is no t contaminated wi th ac ids,alkalis mo istur e or oth er corro sive chem icals. The pr im e coat shal l be app l ied as soon as possible
a f te r t he sur face p repara t ion is comple ted.
2.3 The accept able surf ace preparat ion qual i ty / grades are descr ibed under each paint ing system .
The procedures covered are solvent cleaning, hand tool c leaning, power tool c leaning and blast
cleaning.
2.4 Solvent cleaning
The surface shal l be cleaned by wiping, immersion, spraying or vapor contact ing of a sui tablesolvent o r w ashing wit h an em ulsion o r a lkaline solu t ion to rem ove oi l , grease, d ir t , o ld paint , etc.
Solvent cleaning shal l not remove rust, scales, mi l l scales or weld f lux. Therefore, before
appl icat ion of paint, solvent cleaning shal l be fo l lowed by other cleaning procedures as stated
elsewhere.
2.5 Hand tool cleaning
The surface shal l be cleaned by vigorous w ire brushing done m anual ly to St-2 qual i ty. This meth od
effect ively remo ves loosely adherent m ater ia ls, bu t w ould no t affect residues of ru st or m i l l scales
that a re in tact and f i rm ly adherent .
2.6 Power tool c leaning
Electr ic or pn eum atic t ools shal l c lean t he surface t o St - 3 qual i ty. The t ools shall be u sed careful ly
to prevent excessive roughing of surface and formation of r idges and burns. This method wi l l
remove loosely adherent mater ia ls but would not affect residues of rust or mi l l scales that are
f i rmly adherent .
2.7 Blast clea ning
The surface shal l be cleaned by imp ingement of abrasive mat er ia ls, such as graded sand at h igh
veloci ty created by clean and d ry comp ressed air b last. This m etho d w i l l rem ove loosely adher ent
m ater ia ls as w el l as adheren t scales and m i l l scales. Pr ior to appl icat ion of b last, heavy d eposi t of
o i l and grease are rem oved by solvent cleaning and excessive surface scales are rem oved b y hand
to ols or pow er too l c leaning. The surface shal l be cleaned to Sa - 2 1/ 2 qual i ty i .e. 95 % of surf ace
area is free f rom al l rust, m i l l scales and visib le residues, foreign m ater ia ls, etc. The blast cleaning
is no t recom m ended fo r sheet m eta l w ork.
3.0 PRIM ER PAINTS (P)
Prim er paint s shal l be appl ied on ly on d ry and clean surfaces.
Technical Specificati on: Annexure s Page 31 of 62
12) Electr ical schem atic d iagram s
13) Cable specification s, cables sch edule and cable layou t draw ings.
14) Any o ther st ructura l / m echan ical / e lect r ical e tc . d raw ings / da ta m ent ioned e lsewh ere in the
techn ical specif icat ion as w el l as con sidered necessary by the Purchaser/ Consul tant s.
15) List o f exclusion, i f any from Bidder ’s Scope of W ork.
16) List o f d eviat ions from technical speci f icat ion .
4.0 ELECTRICS
4.1 DRAW INGS/ DOCUM ENT TO BE SU BM ITTED BY THE TEND ERER
Drawings / Data / Document s a long w i th th e B id
1. Deta i led scope o f work wi th genera l descr ip t ion o f the system & equ ipment o f fe red
speci fying the important features and detai led design cr i ter ia and design phi losophy
including fu l l deta i ls of refer ence data, assum pt ions, etc.
2 . Descr ipt ion to be accompanied by single l ine diagrams and equipment layout to enableow ner to have proper apprec ia t ion o f equ ipm ent o f fe red and i ts op era t ion .
3 . Bil l of Quanti t ies (un -pr iced) in speci f ied format, wi th d ivis ion l ist of suppl ies from foreign
and indigenous sources.
4 . List of specif ic exclusions, if an y, from Bidder ’s Scope of W ork.
5 . List of deviat ion s from technical speci f icat ions,
6 . Equipment wise List of commissioning spares and consumables with i tem wise descr ipt ionand quant i ty inc luded in t he main o f f e r .
7 . List o f 2 years operat ion spares, equipm ent w ise (un-pr iced). The l ist shal l indicate
descr ip t ion and quant i ty fo r each i tem .
8 . List of special too ls and t ackles
9. W ork Schedu le wi t h bar chart indicat ing al l act iv i t ies for e lectr ics.
10 . Phase-wise con str uct ion po wer requ iremen ts for erect ion / t est in g act iv i t ies.